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Starter motor - brush and solenoid renewal
Engine electrical systems / Starter motor - brush and solenoid renewal


Note: This procedure assumes that replacement brushes of the correct type have been obtained - at the time of writing, no individual starter motor components were available as separate replacement Ford parts.

An auto electrical specialist should be able to supply parts such as brushes.

The following procedures are for the Lucas/Magneti Marelli unit fitted to the project vehicle - the procedure is essentially the same for the Bosch unit that may be found on other models.

1 Remove the starter motor from the vehicle (Section 16) (see illustration).

17.1 Exploded view of the Bosch DW starter motor
17.1 Exploded view of the Bosch DW starter motor

Brush renewal
2 Remove the brushes as shown (see illustrations).

17.2A Remove the two screws to release the end cap. Withdraw the gasket and
17.2A Remove the two screws to release the end cap. Withdraw the gasket and prise out the C-clip, noting any shims fitted to control armature endfloat . . .

17.2B . . . unscrew the two screws . . .
17.2B . . . unscrew the two screws . . .

17.2C . . . and withdraw the end housing . . .
17.2C . . . and withdraw the end housing . . .

17.2D . . . then unclip the brush holders and springs . . .
17.2D . . . then unclip the brush holders and springs . . .

17.2E . . . unscrew the nut securing the solenoid link . . .
17.2E . . . unscrew the nut securing the solenoid link . . .

17.2F . . . withdraw the negative brushes . . .
17.2F . . . withdraw the negative brushes . . .

17.2G . . . lift off the plastic insulating plate . . .
17.2G . . . lift off the plastic insulating plate . . .

17.2H . . . remove the brushbox and remove the positive brushes complete with
17.2H . . . remove the brushbox and remove the positive brushes complete with the bus bar . . .

17.2I . . . note how the bus bar is engaged on the brushbox before removing
17.2I . . . note how the bus bar is engaged on the brushbox before removing it

3 In some cases, the brushes will have wear limit marks, in the form of a groove etched along one face of each brush; when the brushes are worn down to these marks, they must be renewed. If no marks are provided, measure the length of each brush, and compare it with the minimum length given in the Specifications Section of this Chapter. If any brush is worn below this limit, renew the brushes as a set. If the brushes are still serviceable, clean them with a petrolmoistened cloth. Check that the spring pressure is equal for all brushes, and holds the brushes securely against the commutator.

If in doubt about the condition of the brushes and springs, compare them with new components.

4 Clean the commutator with a petrolmoistened cloth, then check for signs of scoring, burning, excessive wear or severe pitting. If worn or damaged, the commutator should be attended to by an auto-electrician.

5 Refitting is the reverse of the removal procedure.

Solenoid renewal
6 Unscrew the nut, noting the lockwasher(s), and disconnect the motor link from the solenoid terminal.

7 Unscrew the two bolts securing the solenoid to the motor drive end housing.

8 Release the solenoid plunger from the starter engaging lever, then withdraw the solenoid, noting the spring.

9 Refitting is the reverse of the removal procedure. Clean the solenoid, its plunger and the motor/solenoid mating surfaces carefully, and lubricate the plunger/starter engaging lever surfaces with a smear of grease.


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