Contents: Disassembly ↓ Assembly ↓
Disassembly
1. With a socket wrench by 10 mm unscrew the nut securing the wire tip to the terminal (contact bolt) traction relay.
2. Remove the wire tip from the contact bolt of the traction relay.
3. With a socket wrench by 8 mm we unscrew the two bolts securing the traction relay.
4. Remove the traction relay from the starter (in this case it is necessary to disconnect the relay core earring from the upper end of the drive lever).
Recommendation: Check the ease of movement of the traction relay core. Connect an ohmmeter to the terminals of the traction relay and, by pressing the anchor to the stop, make sure that the contact bolts close (electrical resistance is close to zero). The faulty traction relay must be replaced.
5. With a socket wrench by 10 mm we unscrew the two nuts of the tie rods.
6. Carefully disconnect the stator from the front cover and remove the stator from the studs.
7. Remove the central gear of the planetary gearbox (sometimes the gear remains on the armature shaft).
8. Using a slotted screwdriver, remove the three planetary gears of the gearbox one by one.
Recommendation: Check the condition of the 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 faulty gearbox elements (either the drive or the starter assembly).
9. Using a screwdriver, rest against the upper part of the front cover of the starter, 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 drive gear should rotate freely in one direction only, chipped teeth and strong nicks on the lead-in part of the teeth are unacceptable. Minor defects can be removed with a diamond file or an abrasive stone. A faulty and heavily worn drive must be replaced (or starter assembly).
11. With a hammer through an open-end wrench by 13 mm knock down 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 drive assembly with the lever and clutch from the shaft.
14. Using a puller, remove the retaining ring (1) of the drive lever coupling.
15. Remove the washer (2) and the coupling (5) together with the drive lever (3) from the drive (4).
[The text is taken from the online resource: vazbook.ru]
Note: When replacing only the drive, further work on disassembling the starter can be omitted.
16. Using a puller, 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 back cover.
20. Using a slotted screwdriver, remove the brush assembly from the 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 armature windings.
Note: Traces of charring of windings are not allowed - such an anchor must be replaced.
25. Clean the dirty commutator with fine-grained sandpaper, clamping the anchor shaft through a strip of thick paper in the chuck of an electric drill. Wash the anchor with water and detergent to remove dirt, coal 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 a 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 anchor 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 SHRUS-4 grease to the gearbox parts. Before installing the drive, dip it in engine oil and let the oil drain. Lubricate the bushings in which the anchor and drive shafts rotate, as well as the drive screw splines, 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.