Contents: Nippon Denso type ⇊ Mifsuba type ⇊
The replacement is carried out on the starter removed from the vehicle.
Nippon Denso type
This starter has a duplicate reduction gear set that takes up a significant amount of space, and the solenoid is often located inside the starter.
1. Remove the rear cover of the solenoid. Take out the solenoid. There is a spring on its axis and a steel ball at the end of the axis.
2. Remove the bolts securing the end frame to the motor and solenoid housing.
3. Remove the end frame. The overrunning clutch assembly can now be removed along with the drive gear. The idler pulley and drive pinion can be removed separately. There are five ball bearings in the idler pulley gear.
4. The clutch assembly is held in place by a ring clamp. Press down on the pinion against the internal spring and remove the ring clamp with the expander. Remove the thrust ring, pinion, spring and washer from the clutch assembly. To install:
5. Assemble the clutch components and install the ring clamp.
6. Install the gears and clutch assembly. Make sure the five ball bearings are positioned correctly.
7. Install the end frame.
8. Install the center bolts.
9. Install the solenoid. Pay attention to the correct installation of the steel ball on the end of the axle and spring. All sliding surfaces of the solenoid should be lightly coated with a thin layer of grease before installation.
Mifsuba type
1. Remove the three solenoid retaining screws from the front of the mechanism (from the housing cover). Separate the solenoid from the armature plane to disengage from the solenoid lever; remove it and the gasket. Remove any remaining screws holding the mechanism housing.
2. Loosen the bolts securing the end frame and armature housing to the drive body, then remove the transmission housing cover and the housing itself, leaving the armature, brushes and bearings assembled.
3. At the rear, remove the three screws holding the cover to the housing. Remove the housing cover. Now remove the complete overrunning clutch assembly with the drive gear and solenoid lever. Be careful not to knock off or lose the labyrinth tube and its rubber seal.
4. Check the coupling assembly by moving it along the shaft. If the movement is not free and smooth, or if the coupling does not satisfactorily prevent counterclockwise rotation (as viewed from the main drive gear side), replace it.
Installing the starter:
5. Assemble the overrunning clutch assembly and solenoid lever.
6. Install the cover and secure it with screws.
Assemble the unit at the end frame and secure it with bolts.
Install the solenoid, properly positioning and engaging the solenoid lever.
Install the outer mounting screws.
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