Starter motor - brush renewal
Bosch long frame and Cajavec
1 With the starter motor removed from the vehicle and cleaned, grip the unit in a vice fitted with soft jaw protectors.
2 Remove the two screws securing the commutator end housing cap, then remove the cap and rubber seal.
Remove the commutator end housing cap securing screws
3 Wipe any grease from the armature shaft, and remove the C-clip, or E-clip, as applicable, and shims from the end of the shaft.
Remove the C-clip . . .
. . . and shims from the end of the armature shaft
4 Unscrew the two nuts and remove the washers, or remove the securing screws (as applicable), then lift off the commutator end housing.
Remove the commutator end housing securing screws
Commutator end housing removed to expose brush plate
5 Carefully prise the thrust retaining springs from their locations, then slide the brushes from the brush plate.
6 If the brushes have worn to less than the specified minimum, renew them as a set. To renew the brushes, cut the leads at their midpoint and make a good soldered joint when connecting the new brushes.
7 The commutator face should be clean and free from burnt spots. Where necessary, burnish with fine glass paper (not emery) and wipe with a fuel-moistened cloth.
8 On starter motors where the commutator end housing is secured by nuts and washers, position the brush plate over the end of the armature, with the cut-outs in the brush plate aligned with the end housing securing studs.
9 On starter motors where the commutator end housing is secured by screws, position the brush plate over the end of the armature with the cut-outs in the brush plate aligned with the loops in the field windings.
10.9 Align the cut-outs in the brush plate (B) with the loops in the field
windings (A)
The brush plate will be positively located when the commutator end housing screws are fitted.
10 Position the brushes in their respective locations in the brush plate, and fit the brush retaining springs.
11 Guide the commutator end housing into position, at the same time sliding the rubber insulator into the cut-out in the housing. Secure the commutator end housing with the nuts and washers or screws, as applicable.
12 Fit sufficient shims to the end of the armature shaft to eliminate endfloat when the C-clip or E-clip, as applicable is fitted, then fit the clip.
13 Fit the armature shaft bearing seal to the commutator end housing, then apply a little lithium-based grease to the end of the armature shaft and refit the end housing cap, securing with the two screws.
Bosch short frame
14 To remove and refit the brush assembly, proceed as for the Bosch long frame except for the following.
Commutator end housing components - Bosch short frame motor
A Securing screws
B Housing cap
C Spanner
D Shims
E C-clip
F Armature shaft
15 Release the brush holders complete with brushes by pushing the brush holders towards the commutator and unclipping them from the brush plate. Withdraw the brush plate.
Brush plate removal - Bosch short frame motor
A Field brushes
B Terminal brushes
C Brush plate
D Brush holders
16 To renew the brushes, the leads must be unsoldered from the terminals on the brush plate, and the leads of the new brushes must be soldered to the terminals.
17 To refit the brush assembly, position the brush plate over the end of the armature shaft, then assemble the brush holders, brushes and springs, ensuring that the brush holder clips are securely located. The brush plate will be positively located when the commutator end housing screws are fitted.
Lucas
Note: New star clips must be obtained for the armature shaft on reassembly.
18 With the starter motor removed from the vehicle and cleaned, grip the unit in a vice fitted with soft jaw protectors.
19 Remove the plastic cap from the end of the armature shaft, then remove the star clip from the end of the shaft, using a chisel at an angle of 45° to the shaft to distort the prongs of the clip until it can be removed.
Brush assembly - Lucas starter motor
1 Plastic cap
2 Star clip
3 Commutator end plate
securing screw
4 Commutator end plate
5 Brush box
6 Yoke
7 Pole securing screw
8 Solenoid connector link
9 Pole shoe
10 Field coils
20 Unscrew the two securing nuts and remove the connector cable from the main feed terminal.
21 Extract the two commutator end plate securing screws, and carefully tap the end plate to free it. Lift the end plate clear to allow access to the two field brushes. Disconnect the two field brushes from the brush box to allow complete removal of the commutator end plate. Take care not to damage the gasket as the end plate is removed.
22 Remove the nut, washer and insulator from the main terminal stud on the commutator end plate, then push the stud and the second insulator through the end plate and unhook the brushes.
23 To remove the brush box, drill out the rivets securing the brush box to the end plate, then remove the brush box and gasket.
24 If the brushes have worn to less than the specified minimum, renew them as a set. To renew the brushes, cut the leads at their midpoint and make a good soldered joint when connecting the new brushes.
25 The commutator face should be clean and free from burnt spots. Where necessary, burnish with fine glass paper (not emery) and wipe with a fuel-moistened cloth.
26 Commence reassembly by positioning the brush box gasket on the commutator end plate, then position the brush box on the gasket and rivet the brush box to the end plate. Use a new gasket if necessary.
27 Fit the main terminal stud and insulator to the commutator end plate, then secure the stud with the remaining insulator, washer and nut. Fit the two brushes which are attached to the terminal stud into their respective locations in the brush box.
28 Fit the two field brushes into their locations in the brush box, then position the commutator end plate on the yoke and fit the two securing screws.
29 Fit a new star clip to the end of the armature shaft, ensuring that the clip is pressed home firmly to eliminate any endfloat in the armature.
Using a soft faced hammer and socket to fit a new star clip to the end of the
armature shaft - Lucas starter motor
Fit the plastic cap over the end of the armature shaft.
Nippondenso
30 With the starter motor removed from the vehicle and cleaned, grip the unit in a vice fitted with soft jaw protectors.
31 Unscrew the retaining nut and washer and disconnect the wiring from the terminal on the solenoid.
32 Remove the two screws securing the commutator end housing cap and remove the cap.
Brush assembly - Nippondenso starter motor
1 Yoke
2 Solenoid connecting link
3 Pole shoe
4 Rubber grommet
5 Brush
6 Brush spring
7 Brush plate
8 Commutator end housing
9 Bush
10 Spring
11 C-clip
12 Commutator end housing cap
13 Commutator end housing securing bolt
33 Remove the C-clip from the groove in the armature shaft, and remove the spring.
34 Unscrew the two bolts and washers, and withdraw the commutator end housing.
35 Withdraw the two field brushes from the brush plate, then remove the brush plate.
36 If the brushes have worn to less than the specified minimum, renew them as a set. To renew the brushes, cut the leads at their midpoint and make a good soldered joint when connecting the new brushes.
37 The commutator face should be clean and free from burnt spots. Where necessary, burnish with fine glass paper (not emery) and wipe with a fuel-moistened cloth.
38 Position the brush plate over the end of the armature, aligning the cut-outs in the brush plate with the loops in the field windings. The brush plate will be positively located when the commutator end housing bolts are fitted.
39 Fit the brushes to their locations in the brush plate, and retain with the springs.
40 Fit the commutator end housing and secure with the two bolts and washers.
41 Fit the spring and the C-clip to the end of the armature shaft, then smear the end of the shaft with a little lithium-based grease, and refit the commutator end housing cap, securing with the two screws.
42 Reconnect the wiring to the solenoid terminal and fit the washer and retaining nut.