Starter Overhaul (Except J35A7)

Starter Overhaul

J35A6, '07 model J35A7 engines

Disassembly/Reassembly





Brush Holder Removal

1. Remove the starter Starter Removal and Installation (Except J35A7).

2. Disconnect the motor wire from the M terminal Testing and Inspection and remove the end cover.

3. Remove the brush holder (A).






Armature Inspection and Test

4. Disassemble the starter as shown in the exploded view.

5. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.






6. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 7, or recondition with #500 or #600 sandpaper (B).






7. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.










8. Measure the commutator (A) runout.

- If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
- If the commutator runout is not within the service limit, replace the armature.










9. Use a digital caliper or dial caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.










10. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.






11. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.






12. Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.






Starter Brush Inspection

13. Measure the brush length. If it is shorter than the service limit, replace the brush holder assembly.










Starter Brush Holder Test

14. Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.






Planetary Gear Inspection

15. Check the planetary gears (A) and the internal ring gear (B). Replace them if they are worn or damaged.






Overrunning Clutch Inspection

16. Slide the overrunning clutch (A) along the shaft. Replace it if it does not slide smoothly.






17. Hold the overrunning clutch (A), and turn the drive gear (B) in the direction shown to make sure it turns freely. Also make sure the drive gear locks in the opposite direction. If it does not lock, replace the overrunning clutch assembly.





18. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.

Check the condition of the torque converter ring gear. Replace it if the starter drive gear teeth are damaged.

Starter Reassembly

19. Install the armature in the housing.

20. Set the brushes with the brush spring in the brush holder (A).





21. Place the brush holder assembly on the armature, then move the brush holder down to the armature.

NOTE: Keep the brush holder on the armature so the brushes do not come out of the brush holder.

22. Install the end cover to retain the brush holder.






23. Install the starter Starter Removal and Installation (Except J35A7).