Post 802174 by ProStreetDriver on 2016-06-18 17:56:25
[video=youtube;3tN3vhIW3Fc]https://www.youtube.com/watch?v=3tN3vhIW3Fc[/video] Video tutorial on how to rebuild a starter yourself at home. This is a great way to save money considering it’s only about $10 for replacement parts and a rebuilt replacement can around $150 depending on the vehicle. The repair maybe slightly more if you have to replace a solenoid. Tools/Supplies Needed: -new brushes, bushings or bearings, and solenoid -multimeter -600 grit aluminum oxide sandpaper -ratchet and socket set -paint -grease -electrical contact cleaner -wire brush -scraper -clean rags -degreaser -pliers -adjustable wrench -tape -paint marker Procedure: -remove starter from vehicle -tape up any exposed holes on the starter -clean the outside using a scraper and wire brush -use a paint marker to mark any case seams -remove the main power cable coming off the solenoid -remove the outer bolts on the starter case -these are extremely long and small, so take your time as you can risk breaking them depending on the condition of your starter -the starter should pop right apart -do not force the starter apart as there are plastic components which can break -remove the solenoid -the plunger will fit into a plastic fork so it does need to be shifted to one side so it can be removed from the unit -remove rubber cap holding the engagement lever into place, then remove the final drive assembly -the gear reduction just slides apart and inside you will find a series of gears -remove the two bolts on the backside and pull off the cap -remove the small rubber cap on the side that both holds and insulates the cable which just slides out -pull back on the shaft to help assist the armature and brushes out -pop the metal clips back and remove the cap on the brush carrier -fully remove the metal clips and pull the brushes out, be extremely careful not to lose the springs in the process -using a plastic safe degreasing, clean up any old lubricant on any parts with a clean rag -disassemble the final drive, there is a c clip at the end of the shaft that holds the pinion gear in place -remove the pinion gear and clutch assembly, inspect for any damage and replace if necessary -remove another c clip, this time using needle nose plies to separate the final drive shaft -clean up everything again with a degreaser -there will be a bushing inside the case, so inspect that for any damage and replace if necessary -for reassembly, apply a film of grease to any moving parts -use a high quality grease throughout the starter motor, something which will maintaining good lubricating qualities in cold climate and not melt under high heat -the grease will provide lubrication and hold the ball into place, make sure you do not lose it -there will be a bushing in the end cap housing, therefore make sure it is in good condition with not play, replace if necessary -I used a hacksaw blade to cut a slit in the bushing, do not cut all the way through as we do not want to mark the casing -using a chisel, crush the bushing and then you’ll be able to remove it -clean up any old dirt or lubricant -gently insert the new bushing with a hammer, once it becomes a little lower, use the old bushing to help assist it into place and ensure it sits into the same location as before -clean up the armature using electrical contact clean and a tooth brush -commutator resurface using 600 grit aluminum oxide sandpaper and a drill -clean up the commutator using electrical contact cleaner and ensure the spaces between the commutator bars are clean -the mica in these spaces should also be about 1mm lower -using a multimeter, test the armature -wash the inside of the start case with contact cleaner to remove any contaminants -checked the solenoid with a multimeter -for reassembly, install the final drive back into the case -apply a light amount of oil to the oilite bushings if desired -install rubber cap, solenoid and then motor case -install the new bushes in the carrier and seat using 600 grit aluminum oxide sandpaper so they match the contour of the commutator -wash everything with electrical contact cleaner -assembly the starter