Note: Depending on the malfunction that has occurred, the sequence and scope of repair work may be changed.
The most common starter malfunctions:
1. The winding burns out or the contact bolts and contact plate burn in the starter traction relay. To eliminate these faults, it is necessary to replace the starter traction relay. This can be done on the car without removing the starter;
2. The overrunning clutch of the starter drive is faulty. To eliminate this fault, it is necessary to disassemble the starter and replace the drive;
3. The starter brushes are worn out. The starter should be removed from the vehicle, the brush assembly should be replaced, and the commutator should be cleaned. When replacing the brush assembly, there is no need to remove the starter drive and traction relay.
To perform starter repair work you will need:
- two power wires (with clamps on the ends) to jump start the engine from another car's battery;
- release tongs for removing locking rings;
- ohmmeter.
Examination
Note: You can check the electrical part of the starter without disassembling it.
1. Remove the starter from the car.
Helpful Hint: When checking, do not short-circuit the clamp of the wire connected to the positive terminal of the battery to the starter housing. To do this, extend the clamp, for example, by inserting a steel punch into it.
2. Using one wire, connect the negative terminal of the battery to the starter housing. The second wire, connected to the positive terminal of the battery, is connected to the contact bolt (2) of the traction relay, to which the starter wire is connected. If the starter anchor begins to rotate, the starter motor is in good condition.
3. Connect the second wire to the contact bolt (1) of the starter traction relay. Using a screwdriver or other suitable metal object, close the terminal (3) and the contact bolt of the starter traction relay. If you hear a loud click and the starter anchor starts to rotate, the traction relay is working properly.
To further check the starter, as well as to determine the cause of the malfunction, it is necessary to disassemble the starter.
Disassembly
1. Using a 10 mm socket wrench, unscrew the nut securing the wire tip to the terminal (contact bolt) starter traction relay.
2. Remove the wire tip from the contact bolt of the starter traction relay.
3. Using an 8 mm socket wrench, unscrew the two bolts securing the starter traction relay.
4. Remove the traction relay from the starter (in this case it is necessary to disconnect the traction relay core earring from the upper end of the drive lever).
Recommendation. Check the ease of movement of the starter traction relay core. Connect an ohmmeter to the traction relay terminals and, by pressing the anchor all the way in, make sure that the contact bolts close (electrical resistance is close to zero). A faulty starter solenoid relay must be replaced.
5. Using a 10 mm socket wrench, unscrew the two nuts of the tie rods.
6. Carefully disconnect the stator from the front cover of the starter and remove the stator from the studs.
7. Remove the central gear of the starter planetary gearbox (sometimes the gear remains on the armature shaft).
8. Using a slotted screwdriver, remove the three planetary gears of the starter gearbox one by one.
Recommendation. Check the condition of the starter planetary gearbox. The needle bearings of the satellite gears should not be damaged. There should be no chips, burrs, traces of corrosion or other damage on the gearbox teeth. It is necessary to replace the faulty gearbox elements (either the drive or the starter assembly).
9. Using a screwdriver, press against the top of the front cover of the starter and pry up the drive lever support.
10. Remove the drive from the cover together with the drive shaft, drive lever, lever support and external gear of the gearbox.
Recommendation. Check the condition of the drive. The drive should move freely along the shaft splines without jamming. The starter drive gear should be screwed on freely in one direction only, chipped teeth and strong nicks on the lead-in part of the teeth are not allowed. Minor defects can be removed with a diamond file or an abrasive stone. It is necessary to replace a faulty and heavily worn drive (or starter assembly).
11. Using a hammer and a 13 mm open-end wrench, knock off the starter drive travel limiter ring (in this case, a wooden block or a piece of thick rubber should be placed under the gearbox gear).
12. Using a slotted screwdriver, remove the drive travel limiter retaining ring from the groove in the shaft and remove the retaining ring and travel limiter ring from the shaft.
13. Remove the starter drive assembly with the lever and clutch from the shaft.
14. Using special expansion pliers, remove the retaining ring of the drive lever coupling.
15. Remove the washer (2) and the coupling (5) together with the drive lever (3) from the drive (4).
Note: When replacing only the drive, further work on disassembling the starter can be omitted.
16. Using special expansion pliers, remove the drive shaft support retaining ring.
17. From the drive shaft (1), sequentially remove the thrust washer (5), shaft support (4), sealing rubber ring (3) and external gear of the planetary gear (2).
18. Using a Phillips screwdriver, unscrew the two screws securing the brush assembly to the rear cover of the starter.
19. Remove the rear cover of the starter.
20. Using a slotted screwdriver, remove the brush assembly from the starter armature collector.
21. Remove the front support of the anchor shaft.
22. Remove the thrust washer from the armature shaft.
23. Overcoming the force of the magnets, we remove the anchor from the stator.
24. Inspect the commutator and starter armature windings.
Note: Traces of carbonization of the starter windings are not allowed - such an anchor must be replaced.
25. Clean the dirty collector with sandpaper ("zero"), clamping the anchor shaft through a strip of thick paper in the chuck of an electric drill. Wash the starter anchor with water and detergent to remove dirt, carbon dust and abrasive residues and carefully wipe dry with a clean rag, blow with compressed air from a tire pump.
26. Replace worn brushes (the height from the working edge to the outlet is equal to or less than 3.5 mm) and brushes that have mechanical damage.
27. Wash the gearbox and drive parts with white spirit or kerosene.
Assembly
The brush assembly can be installed on the starter armature collector using a special mandrel or tool head of the appropriate size and shape. If they are not available, the brushes can be installed without these devices. To do this:
1. Using two screws, attach the brush assembly to the rear cover of the starter.
2. Lubricate the end of the starter armature shaft with two drops of motor oil.
3. Insert four brushes into the corresponding brush holders. Without inserting the brush springs into the brush holders, place the brush assembly on the armature collector.
4. Using thin-nosed pliers, bend back the outer spring stops of all four brushes.
5. Insert the spring into the brush holder.
6. Holding the spring with a screwdriver, bend the four spring stops with pliers. Install the remaining three springs in the same way.
7. Insert the starter anchor into the stator with the brush assembly and rear cover placed on it (in this case, it is necessary to hold the anchor so that its collector does not come out of engagement with the brush assembly).
Further assembly of the starter is performed in the reverse order of disassembly. In this case, apply plastic grease to the gearbox parts. Before installing the drive, dip it in engine oil and let the oil drain. The bushings in which the anchor and starter drive shafts rotate, as well as the screw splines of the drive, are lubricated with engine oil.
8. To ensure that the starter is assembled correctly, before installation, check its functionality, as shown at the beginning of the section.