Starter Removal and Installation Instructions

Starter Removal and Installation Instructions
Starter Removal and Installation
Instructions
CAUTION: Always use care when working on your vehicle! Do NOT
disconnect any electrical cables or wiring while the engine is running!
WARNING: Before starting work, be sure the vehicle is in Park or
Neutral (for manual transmissions). The parking brake should be set
and wheel chocks should be used under two of the tires!
Removal
1
Make sure that the rest of your electrical system is in good working order.
1) Check to make sure the battery is charged to
12.4-12.6 volts. If it is not, check the battery fluid
level (if it is low, add distilled water to bring the level
up to the fill line) and charge the battery now.
2) Now turn on the headlights if the voltage drops
below 12.1v, the battery may be bad.
2
Disconnect the negative (-) battery cable from
the battery.
WARNING: NEVER disconnect the battery cable with
the engine running! This could be dangerous to you
and damage your charging system!
30
Corroded/Loose connections. Spliced on
cable terminals are a common source of
problems. Replace bad cables and clean
all corrosion from terminal ends and
cables.
Instructions cont.
3
Remove the start terminal lead (small lead).
This lead may be attached to the starter with a
spade connector, plug, nut, or screw.
NOTE: Many Ford or Motorcraft starters will
NOT have an start terminal (if so, move on to
step 4).
CAUTION: Some vehicles have a relay (or
R) terminal lead. This lead may look very
similar to the start terminal lead. If this
second lead exists mark it and the
corresponding terminal on the starter with a
piece of tape or some white out. This will
eliminate confusion when it comes time to
install your new starter.
4
Remove positive (+) cable from the starter.
This cable
will be
secured to
the
starter's
solenoid
with a
large nut.
Some
starters
may have
a rubber
boot
covering
the nut.
5
Start
Terminal
+ Cable
Terminal
Don't
Remove
Remove mounting bolts or hardware and remove starter from vehicle.
The mounting bolts may be accessible from
either the starter side or the bell housing
side (as shown in the photo).
1) Remove all mounting bolts and
hardware, 2) slide the starter out of the
vehicle.
2
1
NOTE: In some vehicles it may be
necessary to rotate or change the angle
of the starter or loosen the exhaust
system to get enough clearance to slide
the starter out. Refer to a repair manual
or contact Technical Hotline
(800-228-9672) if you encounter
difficulty.
31
Instructions cont.
Make sure you have the correct part number for your vehicle. Hold the two starters up side by
side and inspect for differences in the "Key Check Points".
6
Key Check Points
Are the mounting
holes the same
size and thread
type ?
Does the start
terminal look
the same?
Is the + cable
post in the same
place.
Does the pinion
gear have the
same number of
teeth?
CAUTION: Some starters may look different, but may be correct. If you are not sure you
have the right one, call the Technical Support Line at (800) 228-9672.
Installation
CAUTION: CHECK THE CONDITION OF THE FLYWHEEL NOW!
A damaged flywheel will cause a good starter to make noise and go bad. Now is the time to check
your flywheel teeth-- while the starter is out.
A) Use a flashlight to look inside the hole where the nose of the starter sits (use a mirror if
necessary). Look for uneven wear: chipped, missing or severely rounded teeth.
B) Using a large screw driver rotate the flywheel until a new set of teeth are visible. Repeat this
process until all teeth have been inspected. Replace flywheel as necessary.
7
Mounting Starter.
HINT: Start all mounting bolts
by hand and tighten finger
tight. This will make it easier to
start all of the bolts and will
prevent damage to your new
starter from cross threading or
cracked mounting ears.
1) Position starter in bell
housing.
2) Secure with mounting bolts
or hardware.
32
2
1
Instructions cont.
8
Install the electrical connections. Install the positive (+) cable and start terminal lead.
NOTE: DO NOT OVER TIGHTEN the positive (+)
battery connection. This may break the solenoid cap
damaging your new starter.
+ Cable
Terminal
Start
Terminal
CAUTION: Some starters may have a relay (or R)
terminal. These terminals may look very similar. If
this second lead exists use the mark described in
step 3 to determine which lead goes on which
terminal. If the leads are similar, but not marked,
refer to the Start Lead Test in the Basic Trouble
Shooting section that follows.
9
Re-connect the battery (-) cable and
start the engine. Start the vehicle
3 more times to be sure the new starter
is working properly. If the vehicle
doesn't start or produces a grinding
noises, refer to the Basic Trouble
Shooting section below.
NOTE: Your new starter will probably sound
slightly different than your old one, since it has a
new/re-manufactured pinion gear. The new pinion
gear will produce a different tone when engaging
with the old flywheel.
Basic Trouble Shooting
CAUTION: Before doing any trouble shooting or tests, be sure the transmission is in
Park or Neutral. (if manual transmission) and the parking brake is set.
The ignition key should be in the off position unless specified otherwise below.
CAUTION: Before starting any trouble shooting check the battery , its cables and
connections (refer to Removal step 1). Without a good battery with a full charge it is
NOT possible to trouble shoot the system!
Problem: ENGINE DOESN'T TURN OVER (NO SOUND)
Start Lead Test. Disconnect the start terminal lead
from the starter. Using a volt meter, place the (+)
red probe against the end of the start lead on the
vehicle. Place the (-) black probe on the bare
metal housing of the starter case. While doing this
have a friend turn the ignition key to the FULL
start position.
If the meter reads:
a) 0.0-12.1v.
1) There is a problem with the start circuit that
runs through your ignition switch. This should
be diagnosed and repaired by a qualified auto
electrician.
2) Or, the Start terminal and R terminal leads
have been installed to the wrong terminals.
Start
terminal
lead
Ground
Start
terminal
33
Instructions cont.
9 cont.
HINT: If you are not sure which lead is the start terminal lead and which is the R (relay)
terminal lead, perform the following test.
First disconnect both leads from the starter. While a friend holds the key in the Full start
position, check for a voltage at the terminal end of each lead. The lead with a voltage is
the start terminal lead. The one without a voltage is the R terminal lead.
b) 12.2-12.6v. Call the Technical Support Line for further assistance.
Problem: ENGINE DOESN'T TURN OVER (BUT MAKES "CLICK" SOUND)
Positive Cable Test (does NOT include vehicles
with remote mounted solenoid, such as those
with early Motorcraft).
Remove the positive (+) cable from the starter.
Using a volt meter, place the red (+) probe on the
cable end and the black (-) probe on the bare
metal housing of the starter.
If the meter reads:
a) 0.0-12.1v. There is a problem with the positive
(+) cable or its connections. Check the whole
cable from the battery to the starter. Make sure
all connections are clean and tight. Also check for
a burned fusible link. This is done by looking for
soft spots or melted insulation along the cable. If
the cable or any part of it are in poor condition
replace with factory style cable.
b) 12.2-12.6v. Call Technical Support for further
assistance.
Positive
cable
terminal
Ground
Positive
terminal
Problem: LOUD GRINDING NOISES
Inspect the flywheel teeth. With the starter in the vehicle this is best done by a transmission shop. There will
probably be a small charge for this service, but if you flywheel is damaged they can perform the necessary work.
If your flywheel teeth have not been damaged, remove the starter and verify that you have the correct starter for
the vehicle though the Technical Support Line.
Problem: ENGINE TURNS OVER VERY SLOWLY
Inspect all positive and negative connections. Slow turn over usually is the result of either a weak battery or poor
electrical connections. Refer to Removal step 1. Additionally, check the following connections:
a) battery negative (-) cable to engine block
b) starter to engine block (paint, oil or other foreign material can weaken this connection)
c) positive cable (battery to starter). Check for loose or dirty intermediate connections, such as at a relay or
junction box. Also look for any sign that this cable may be shorting to ground. If the cable or any parts of it are in
poor condition, replace with factory style cable.
For further assistance call the Technical Support Line at (800) 228-9672.
34
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