Ford Falcon. Manual — part 194

303-06-13 Starting

System 303-06-13

GENERAL PROCEDURES (Continued)

2. It is recommended that the commutator be turned 2. Examine drive end housing mounting surfaces

in two stages, that is pre turning and finish

and threaded holes for damage.

turning. In the pre turning stage the commutator is Drive shaft and planetary assembly inspection

undercut to a maximum depth of 0.8mm.

1. Carefully examine the assembly for signs of wear

NOTE: It is most important to use dust extraction

or cracking.

when undercutting commutators.

2. If worn replace the whole planetary drive. The

3. After undercutting the commutator place the

planetary gear hub and bush may be replaced

armature in the lathe and finish cut using a fine

separately if required.

tool. The cut should be no more than 0.03mm.

3. To replace the hub remove the circlip and thrust

After turning, brush out the commutator slots

washer and withdraw the planetary shaft. To

using a stiff brush and polish surface if necessary.

reassemble reverse the procedure.

NOTE: Runout should be less than 0.1mm for the

NOTE: The planetary gears are pre lubricated, a

commutator and 0.5mm for the laminations.

small amount of light oil may be used to lubricate

Drive end and commutator end bushes

the armature spigot bushing prior to reassembly.

The helix for the drive assembly must be

NOTE: Replace bushes whenever excessive

lubricated with lithium based grease only.

armature shaft side play is evident. If bushes are

excessively worn the starter motor is likely to operate

Drive assembly inspection

inefficiently or the armature may foul the pole pieces.

1. Inspect the pinion for signs of wear or chipped

1. Remove both the commutator end housing and

teeth.

drive end bush by carefully tapping out with a

2. Rotate the pinion by hand and check for any signs

mandrel. Be sure that the commutator end

of roughness or slipping, examine the pinion bush

cover/drive end housing is well supported.

for wear or scoring, if in doubt replace the drive

This can be achieved by soaking the bushes over

assembly.

night in mineral oil. If time does not permit over

Contact burn off reserve testing

night soaking oil can be forced into the bush by

placing a thumb over one end of the bush and

1. Press the plunger until the contacts close, this will

filling it with oil. Using the other thumb press firmly

be indicated when the test lamp comes on.

until the oil is visible on the outer surfaces of the

2. It must be possible to push the plunger another

bush.

1mm or more towards the magnetic core. If less

NOTE: Note that the bushings used in starter

than 1 mm the solenoid must be replaced.

motors are made from porous sintered metal and

Interwinding short circuit testing

as such they will hold oil to provide lubrication. It

is important that the bushes are pre lubricated

1. A 24 volt supply is required for this test. Apply

prior to fitting.

positive supply to terminal 30 (main battery supply

input) and negative to the casing.

2. New bushes may be pressed or tapped into

2. Press the plunger fully home.

position using a suitably sized shouldered

mandrel. Do not ream bushes after installation as 3. Release the plunger, it should return to it’s rest

the self lubricating qualities will be impaired.

position by the action of the return spring. If it

does not the windings have inter winding short

circuits.
NOTE: When the solenoid is connected in this

way the windings are differentially compounded,

that is, their fields are in opposition to each other.

Drive end housing & Commutator end cover

inspection

1. Inspect the housing and cover for damage, wear

or cracking.

G86731 en

303-06-14 Starting

System 303-06-14

REMOVAL AND INSTALLATION

Starter Motor

Removal
1. Disconnect Battery Negative Ground Cable.
2. Raise vehicle on hoist.
3. Disconnect starter cable and solenoid connector.
4. Remove starter retaining bolts and withdraw

starter.

Installation
1. Position starter and install retaining bolts. Torque

to Specification.

2. Install starter cable and solenoid connection.
3. Lower

Hoist.

4. Reconnect Battery Negative Ground Cable.

G86732 en

303-06-15 Starting

System 303-06-15

DISASSEMBLY AND ASSEMBLY

Starter Motor

G86733 en

303-06-16 Starting

System 303-06-16

DISASSEMBLY AND ASSEMBLY (Continued)

5. Using a pair of circlip pliers expand the stop ring

Item

Description

and remove it from the planetary drive shaft taking

1

Drive end shield

care not to damage the shaft.

2

Solenoid

6. Carefully remove any burrs from the planetary

3

Parts set, solenoid

drive shaft before removing the drive assembly,

failure to do so will damage the drive assembly

4

Overrunning clutch drive

internal bush.

5

Fork bearing

6

Epicycloidal gear train

Solenoid Switch

7

Gear hub

1. Disconnect the main braided cable from the short

8

Closure cap

threaded terminal (13mm spanner).

9

Hexagon screw

2. Remove the 3 mounting screws withdraw the

10

Sintered - Metal bushing

solenoid, disengage the plunger from the fork

lever and remove complete with the plunger and

11

Commutator end shield

spring.

12

Brush holder

NOTE: Solenoid position relative to drive end

13

Armature

housing.

14

Pole housing

15

Needle bushing

Drive End Housing

1. Loosen and remove through bolts (7mm socket).

Starter Drive Assembly

2. Withdraw the drive end housing complete with the

planetary gear assembly, drive assembly and fork

Special Tool(s)

lever from the armature gear taking care not to

Bosch fixture

disengage the cover plate.

KDAL 5047

Armature

Special Tool(s)

Bosch fixture

KDAW 9999

Bosch fixture

KDAL 5028

Bosch tool

KDAL 5048

1. Clamp the mounting lug of the drive end housing

in the vice using soft jaws.

2. Remove the rubber sealing block. Remove the

planetary drive assembly, fork lever and planetary

drive from the drive end housing.

3. Ease fork lever from the drive assembly. In order

1. Clamp the pole housing in a vice using soft jaws

to avoid damage to the planetary gears when

or Bosch clamping fixture KDAW 9999.

removing the stop ring use Bosch fixture KDAL

2. Remove the screws and the dust cover cap from

5047 this supports the output shaft and prevents

the commutator end cover.

the shock being absorbed by the planetary gear

3. Remove the rubber ring, circlip and adjustment

hub.

washers.

4. Using Bosch striking sleeve KDAL 5028 and a

4. Slide commutator end cover from armature shaft.

non metallic hammer, with a sharp tap drive back

5. Using special Bosch tool KDAL 5048, slide tool

the stop ring retainer.

onto the armature shaft until it contacts the face of

Alternatively clamp the protruding end of the

the commutator.

planetary drive shaft in a vice (using soft jaws)

and prise the stop ring retainer towards the drive

assembly.

G86733 en