Ford Festiva. Instruction — part 31

Fig. 3: Testing Voltage Drop

Courtesy of FORD MOTOR CO.

STARTER GROUND CIRCUIT TEST

1. Disconnect and ground coil wire from distributor cap to prevent engine from starting. Connect remote starter switch between starter

solenoid terminal "S" and battery positive terminal. See

Fig. 1

.

2. Using a digital voltmeter set on low scale, connect positive voltmeter to starter motor housing. Ensure connection point is clean and free

of rust and grease. Connect negative voltmeter lead to negative battery terminal.

3. Engage remote starter switch and crank engine. Observe and record voltmeter reading. Voltmeter should read .2 volt or less. If voltage

drop is greater than .2 volt, clean negative battery cable connections at battery and body connections. Retest to ensure problem has been
corrected.

4. If voltage drop is still excessive, replace negative battery cable(s) as necessary. If battery cables test okay, and starter still cranks slowly

or not at all, remove and repair starter motor.

BENCH TESTING

STARTER NO-LOAD TEST

Remove starter. Place starter on bench. Connect a fully charged 12-volt battery, voltmeter, ammeter and remote starter switch to starter. See

Fig. 4

. Engage remote starter switch. Starter should rotate smoothly. Ensure voltage and amperage draw is less than maximum specification at

5000 RPM minimum. See NO-LOAD TEST SPECIFICATIONS table. If voltage and/or amperage is higher than specifications, disassemble
starter and determine cause.

NO-LOAD TEST SPECIFICATIONS

NOTE:

Make all voltmeter connections at component terminal rather than at cable or wire end.

Application

Maximum Amps

Volts

Capri & Festiva

60

11.5

Fig. 4: Starter No-Load Test

Courtesy of FORD MOTOR CO.

PINION GAP ADJUSTMENT TEST

1. Disconnect field lead from terminal "M" of solenoid to prevent starter from turning. See

Fig. 5

. Connect jumper wire from a 12-volt

battery positive terminal to terminal "S" of solenoid. Connect another jumper wire from negative battery terminal to terminal "M" of
solenoid.

2. Solenoid should energize when battery is connected, kicking out drive pinion. With drive pinion extended, measure pinion gap between

drive pinion and collar. Gap should be .020-.080" (.5-2.0 mm). See

Fig. 5

.

3. Add or subtract shims between solenoid and end housing to achieve proper pinion depth gap. Install field lead to terminal "M" of

solenoid. Install nut and tighten to 70-106 INCH lbs. (8-12 N.m).

Fig. 5: Measuring Pinion Gap

Courtesy of FORD MOTOR CO.

NOTE:

DO NOT engage solenoid for more than 10 seconds. If test must be repeated, wait at least 3
minutes between tests to allow solenoid to cool.

SOLENOID TEST

Disconnect wiring and cables from solenoid. Using an ohmmeter, check for continuity between terminal "M" and body of starter solenoid. See

Fig. 1

. Continuity should exist. If continuity does not exist, replace solenoid.

ARMATURE TEST

1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade

is attracted to core or if it vibrates, replace armature.

2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, replace

armature. Check continuity between commutator and shaft. If continuity exists, replace armature.

3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

COMMUTATOR TEST

1. Clean surface of commutator and polish with No. 400 grit sandpaper (if required). If surface is scored, out of round or pitted, turn

commutator on a lathe.

2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. See

STARTER

MOTOR SPECIFICATIONS

table.

3. Commutator mica undercut depth should be .02-.03" (.5-.8 mm). If undercut depth is not within specification, undercut with a hacksaw

blade to standard depth.

BRUSH & SPRING TEST

1. Connect ohmmeter between positive brush holder and negative brush holder. If ohmmeter indicates continuity, brush holder assembly is

shorted and must be replaced.

2. Check brush length. See

STARTER MOTOR SPECIFICATIONS

table. If brush length is less than specification, replace brushes.

3. Check spring tension. Spring tension should be 2.0-4.3 Lbs. (8.8-19.1 N.m). Ensure brushes move freely in holders.

FIELD COIL TEST

1. Connect ohmmeter between field lead and soldered portion of brush lead. If continuity does not exist, repair or replace field coil.
2. Check field coil for shorts to ground by connecting ohmmeter between field lead and starter housing. If continuity exists, repair or

replace field coil.

OVERHAUL

Fig. 6: Exploded View of Starter Motor Assembly

Courtesy of FORD MOTOR CO.

STARTER MOTOR SPECIFICATIONS

STARTER MOTOR SPECIFICATIONS

NOTE:

For exploded view of starter assembly, see

Fig. 6

.

Application

Specification

Brush Length

Minimum

.45" (11.5 mm)

New

.67" (17 mm)

Brush Spring Force

2.0-4.3 Lbs. (8.8-19.1

N.m)

Commutator

Runout

.002" (.05 mm)

Minimum Diameter

1.22" (31.0 mm)

Segment Depth

.02-.03" (.5-.8 mm)

Pinion Gap

.020-.080" (0.5-2.0

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

mm)

Application

Ft. Lbs. (N.m)

Starter Motor Mounting Bolts

23-34 (31-46)

INCH Lbs. (N.m)

Solenoid Retaining Screws

36-67 (4.1-7.5)

Through Bolts

55-75 (6-8)

Terminal Nuts

71-106 (8-12)

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