torque ACURA CSX 2006 Service Repair Manual

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INTRODUCTION
How to Use This Manual
Safety Messages
Safety Labels
Safety Messages
Instructions
HONDA MOTOR CO., LTD.
Service Publication Office
As sections with * include SRS components;
special precautions are required when servicing.
This manual is divided into multiple sections. The first page of
each section is marked with a black tab that lines up with its
corresponding thumb index tab on this page and the back cover.
You can quickly find the first page of each section without
looking through a full table of contents. The symbols printed at
the top corner of each page can also be used as a quick
reference system.
Each section includes: 1. A table of contents, or an exploded view index showing:  Parts disassembly sequence.
 Bolt torques and thread sizes.
 Page references to descriptions in text.
2. Disassembly/assembly procedures and tools.
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Your safety, and the safety of others, is very important. To help
you make informed decisions, we have provided safety
messages, and other safety information throughout this manual.
Of course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle. You must use
your own good judgment.
You will find important safety information in a variety of forms
including:  on the vehicle.
 preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
 how to service this vehicle correctly and safely.
All information contained in this manual is based on the latest
product information available at the time of printing. We reserve
the right to make changes at anytime without notice. No part of
this publication may be reproduced, or stored in a retrieval
system, or transmitted, in any form by any means, electronic,
mechanical, photocopying, recording, or otherwise, without the
prior written permission of the publisher. This includes text,
figures, and tables.
As you read this manual, you will find information that is
preceded by a symbol. The purpose of this message is
to help prevent damage to your vehicle, other property, or the
environment.
First Edition 10/2008
All Rights Reserved
Specifications apply to Canada
Specifications Maintenance
*Engine Electrical
Fuel and Emissions
*Transaxle
*Steering
*Body
*Body Electrical
*Restraints *Audio, Navigation,
and Telematics
General Information
Engine Mechanical
Engine Cooling
Brakes
(Including VSA)
*Heating, Ventilation, and Air ConditioningSuspension
(Including TPMS)
08/08/21 14:05:21 61SNR030_000_0002
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Automatic Transmission and A/T Differential
Item Measurement QualificationStandard or New Service Limit
2-12Standards and Service Limits
Automatic
transmission
fluid
Capacity
Use Acura ATF-Z1
Fluid change 2.9 L (3.1 US qt)
Overhaul 6.5 L (6.9 US qt)
ATF pressure Line pressure At 2,000 rpm in P or N900 960 kPa
(9.2 9.8 kgf/cm , 130 140 psi) 850 kPa
(8.7 kgf/cm , 120 psi)
1st clutch pressure At 2,000 rpm in 1st gear in S890 970 kPa
(9.1 9.9 kgf/cm , 130 140 psi) 840 kPa
(8.6 kgf/cm , 120 psi)
2nd clutch pressure At 2,000 rpm in 2nd gear in S890 970 kPa
(9.1 9.9 kgf/cm , 130 140 psi) 840 kPa
(8.6 kgf/cm , 120 psi)
3rd clutch pressure At 2,000 rpm in 3rd gear in S890 970 kPa
(9.1 9.9 kgf/cm , 130 140 psi) 840 kPa
(8.6 kgf/cm , 120 psi)
4th clutch pressure At 2,000 rpm in 4th gear in S890 970 kPa
(9.1 9.9 kgf/cm , 130 140 psi) 840 kPa
(8.6 kgf/cm , 120 psi)
5th clutch pressure At 2,000 rpm in 5th gear in S890 970 kPa
(9.1 9.9 kgf/cm , 130 140 psi) 840 kPa
(8.6 kgf/cm , 120 psi)
Torque converter Stall speed Check with vehicle on level ground 2,150 rpm 2,000 2,300 rpm
Clutch Clearance between clutch end-plate and top disc 1st 1.23 1.43 mm (0.048 0.056 in.)
2nd 0.75 0.95 mm (0.030 0.037 in.)
3rd 0.83 1.03 mm (0.033 0.041 in.)
4th, 5th 0.73 0.93 mm (0.029 0.037 in.)
Clutch return spring free length 1st, 2nd, 3rd 50.8 mm (2.00 in.) 48.8 mm (1.92 in.) 4th, 5th 33.5 mm (1.32 in.) 31.5 mm (1.24 in.)
Clutch disc thickness 1.94 mm (0.076 in.)
Clutch plate thickness 1st, 2nd, 3rd 2.0 mm (0.079 in.) When discolored 4th, 5th 2.3 mm (0.091 in.) When discolored
Clutch wave-plate phase difference 0.07 0.20 mm (0.003 0.008 in.) 0.05 mm (0.002 in.)
1st, 3rd clutch end-plate thickness Mark 1 2.3 mm (0.091 in.) When discolored Mark 2 2.4 mm (0.094 in.) When discolored
Mark 3 2.5 mm (0.098 in.) When discolored
Mark 4 2.6 mm (0.102 in.) When discolored
Mark 5 2.7 mm (0.106 in.) When discolored
Mark 6 2.8 mm (0.110 in.) When discolored
Mark 7 2.9 mm (0.114 in.) When discolored
Mark 8 3.0 mm (0.118 in.) When discolored
Mark 9 3.1 mm (0.122 in.) When discolored
Mark 10 3.2 mm (0.126 in.) When discolored
Mark 11 3.3 mm (0.130 in.) When discolored
Mark 12 3.4 mm (0.134 in.) When discolored
2nd clutch end-plate thickness Mark 1 2.6 mm (0.102 in.) When discolored Mark 2 2.7 mm (0.106 in.) When discolored
Mark 3 2.8 mm (0.110 in.) When discolored
Mark 4 2.9 mm (0.114 in.) When discolored
Mark 5 3.0 mm (0.118 in.) When discolored
Mark 6 3.1 mm (0.122 in.) When discolored
Mark 7 3.2 mm (0.126 in.) When discolored
Mark 8 3.3 mm (0.130 in.) When discolored
Mark 9 3.4 mm (0.134 in.) When discolored
2 2
2 2
2 2
2 2
2 2
2 2
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Automatic Transmission and A/T Differential (cont’d)
Item Measurement QualificationStandard or New Service Limit
2-14Standards and Service Limits
Countershaft Diameter of needle bearing contact
area At torque
converter
housing36.005 36.015 mm
(1.4175 1.4179 in.)
At 4th gear collar 34.982 34.998 mm (1.3772 1.3779 in.)
At reverse gear
collar 39.979 40.000 mm
(1.5740 1.5748 in.)
I.D. of gears 4th gear 41.000 41.016 mm (1.6142 1.6148 in.)
Reverse gear 46.000 46.016 mm (1.8110 1.8117 in.)
End play of gears 5th gear 0 0.48 mm (0 0.019 in.) 4th gear 0.04 0.12 mm (0.002 0.005 in.)
Reverse gear 0.10 0.25 mm (0.004 0.010 in.)
Distance collar length 54.22 54.30 mm (2.135 2.138 in.)
Reverse selector hub width 25.45 25.65 mm (1.002 1.010 in.)
Reverse selector hub O.D. 55.87 55.90 mm (2.200 2.201 in.)
Secondary shaft Diameter of needle bearing contact area At 1st gear 39.986 39.999 mm (1.5742 1.5748 in.)
At 2nd gear 39.986 39.999 mm (1.5742 1.5748 in.)
At 3rd gear collar 36.975 36.991 mm (1.4557 1.4563 in.)
I.D. of gears 1st gear 47.000 47.016 mm (1.8504 1.8510 in.) 2nd gear 46.000 46.016 mm (1.8110 1.8117 in.)
3rd gear 43.000 43.016 mm (1.6929 1.6935 in.)
End play of gears 1st gear 0.04 0.12 mm (0.002 0.005 in.) 2nd gear 0.04 0.12 mm (0.002 0.005 in.)
3rd gear 0.10 0.22 mm (0.004 0.009 in.)
37 x 58 mm thrust washer thickness No. 1 3.900 mm (0.154 in.) No. 2 3.925 mm (0.155 in.)
No. 3 3.950 mm (0.156 in.)
No. 4 3.975 mm (0.156 in.)
No. 5 4.000 mm (0.157 in.)
No. 6 4.025 mm (0.158 in.)
No. 7 4.050 mm (0.159 in.)
No. 8 4.075 mm (0.160 in.)
No. 9 4.100 mm (0.161 in.)
No. 10 4.125 mm (0.162 in.)
No. 11 4.150 mm (0.163 in.)
No. 12 4.175 mm (0.164 in.)
No. 13 4.200 mm (0.165 in.)
No. 14 4.225 mm (0.166 in.)
No. 15 4.250 mm (0.167 in.)
No. 16 4.275 mm (0.168 in.)
No. 17 4.300 mm (0.169 in.)
No. 18 4.325 mm (0.170 in.)
No. 19 4.350 mm (0.171 in.)
No. 20 4.375 mm (0.172 in.)
40 x 51.5 mm thrust washer thickness No. 1 4.80 mm (0.189 in.) No. 2 4.85 mm (0.191 in.)
No. 3 4.90 mm (0.193 in.)
No. 4 4.95 mm (0.195 in.)
No. 5 5.00 mm (0.197 in.)
No. 6 5.05 mm (0.199 in.)When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
08/08/21 14:07:16 61SNR030_020_0014
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Item
Measurement QualificationStandard or New Service Limit
2-15
Secondary shaft
(cont’d)3rd gear collar length 43.9 44.0 mm (1.728 1.732 in.)
Length of 3rd gear collar flange from
end 5.25 5.40 mm (0.207 0.213 in.)
Sealing ring thickness 1.91 1.97 mm (0.0752 0.0776 in.) 1.86 mm (0.0732 in.)
Width of sealing ring groove 2.025 2.060 mm (0.0797 0.0811 in.) 2.080 mm (0.0819 in.)
Clutch feed pipe O.D. 3rd clutch feed pipe11.47 11.48 mm (0.4516 0.4520 in.) 11.45 mm (0.4508 in.)
1st clutch feed
pipe 6.97 6.98 mm (0.2744 0.2748 in.) 6.95 mm (0.2736 in.)
Clutch feed pipe bushing I.D. 3rd clutch feed pipe11.500 11.518 mm (0.4528 0.4535 in.) 11.530 mm (0.4539 in.)
1st clutch feed
pipe 7.018 7.030 mm (0.2763 0.2768 in.) 7.045 mm (0.2774 in.)
ATF guide of sealing ring contact I.D. 29.000 29.021 mm (1.1417 1.1426 in.) 29.05 mm (1.144 in.)
Idler gear shaft Diameter of needle bearing contact area End cover side 32.003 32.013 mm (1.2600 1.2604 in.)
Thickness of cotters 1.39 1.42 mm (0.0547 0.0559 in.)
Reverse idler
gear Reverse idler gear shaft diameter at
needle bearing contact area 14.99 15.00 mm (0.5902 0.5906 in.)
I.D. 20.007 20.020 mm (0.7877 0.7882 in.)
I.D. of reverse idler gear shaft contact
area on transmission housing 14.800 14.818 mm (0.5827 0.5834 in.)
I.D. of reverse idler gear shaft holder 14.800 14.824 mm (0.5827 0.5836 in.)
ATF pump ATF pump thrust clearance 0.03 0.06 mm (0.001 0.002 in.) 0.07 mm (0.003 in.) Clearance between ATF pump gear
and body Drive gear 0.210 0.265 mm (0.0083 0.0104 in.)
Driven gear 0.070 0.125 mm (0.0028 0.0049 in.)
ATF pump driven gear I.D. 14.016 14.034 mm (0.5518 0.5525 in.)
ATF pump driven gear shaft O.D. 13.980 13.990 mm (0.5504 0.5508 in.)
Stator shaft Needle bearing contact I.D. Torque converter side27.000 27.021 mm (1.063 1.064 in.)
ATF pump side 29.000 29.021 mm (1.1417 1.1426 in.)
Sealing ring contact area I.D. 29.000 29.021 mm (1.1417 1.1426 in.) 29.05 mm (1.144 in.)
Reverse shift
fork Fork finger thickness 5.90 6.00 mm (0.232 0.236 in.) 5.40 mm (0.213 in.)
Park gear and
pawl
Servo body Shift fork shaft bore I.D. 14.000 14.010 mm (0.5512 0.5516 in.) Shift fork shaft valve bore I.D. 37.000 37.039 mm (1.4567 1.4582 in.) 37.045 mm (1.4585 in.)
Regulator valve
body Sealing ring contact I.D. 29.000 29.021 mm (1.1417 1.1426 in.) 29.05 mm (1.144 in.)
(cont’d)
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
When worn or damaged
08/08/21 14:07:16 61SNR030_020_0015
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Automatic Transmission and A/T Differential (cont’d)
ItemMeasurement Qualification Standard or New
Wire Diameter O.D. Free Length No. of Coils
2-16 Standards and Service Limits
Main valve body
spring (see page
14-303)
Shift valve A spring 0.8 mm
(0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Shift valve B spring 0.8 mm (0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Shift valve C spring 0.8 mm (0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Relief valve spring 1.0 mm (0.039 in.)9.6 mm
(0.378 in.)34.1 mm
(1.343 in.) 10.2
Lock-up control valve spring 0.65 mm (0.026 in.)7.1 mm
(0.280 in.)23.1 mm
(0.909 in.) 12.7
Cooler check valve spring 0.85 mm (0.033 in.)6.6 mm
(0.260 in.)27.0 mm
(1.063 in.) 11.3
Servo control valve spring 0.7 mm (0.028 in.)6.6 mm
(0.260 in.)35.7 mm
(1.406 in.) 17.2
Shift valve E spring 0.8 mm (0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
Regulator valve
body spring
(see page
14-305) Stator reaction spring 4.5 mm
(0.177 in.)35.4 mm
(1.394 in.)30.3 mm
(1.193 in.) 1.92
Regulator valve spring A 1.9 mm (0.075 in.)14.7 mm
(0.579 in.)80.6 mm
(3.173 in.) 16.1
Regulator valve spring B 1.6 mm (0.063 in.)9.2 mm
(0.362 in.)44.0 mm
(1.732 in.) 12.5
Torque converter check valve spring 1.2 mm (0.047 in.)8.6 mm
(0.339 in.)33.8 mm
(1.331 in.) 12.2
Lock-up shift valve spring 1.0 mm (0.039 in.)6.6 mm
(0.260 in.)35.5 mm
(1.398 in.) 18.2
3rd accumulator spring 2.5 mm (0.098 in.)14.6 mm
(0.575 in.)29.9 mm
(1.177 in.) 4.9
1st accumulator spring A 2.4 mm (0.094 in.)18.6 mm
(0.732 in.)49.0 mm
(1.929 in.) 7.1
1st accumulator spring B 2.3 mm (0.091 in.)12.2 mm
(0.480 in.)31.5 mm
(1.240 in.) 6.6
Servo body
spring (see page
14-306) Shift valve D spring 0.8 mm
(0.031 in.)5.6 mm
(0.220 in.)28.1 mm
(1.106 in.) 15.9
4th accumulator spring B 2.3 mm (0.091 in.)12.2 mm
(0.480 in.)31.5 mm
(1.240 in.) 6.6
4th accumulator spring A 2.4 mm (0.094 in.)18.6 mm
(0.732 in.)49.0 mm
(1.929 in.) 7.1
2nd accumulator spring B 2.0 mm (0.079 in.)10.6 mm
(0.417 in.)34.0 mm
(1.339 in.) 8.0
2nd accumulator spring A 2.2 mm (0.087 in.)16.6 mm
(0.654 in.)48.2 mm
(1.898 in.) 8.5
5th accumulator spring 2.5 mm (0.098 in.)14.6 mm
(0.575 in.)29.9 mm
(1.177 in.) 4.9
08/08/21 14:07:17 61SNR030_020_0016
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Item
Measurement QualificationStandard or New Service Limit
2-17
A/T differential
carrierPinion shaft contact area I.D. 18.000 18.025 mm (0.709 0.710 in.)
Clearance between carrier and pinion
shaft 0.013 0.054 mm (0.001 0.002 in.) 0.1 mm (0.004 in.)
Driveshaft contact area I.D. 28.015 28.045 mm (1.103 1.104 in.)
Clearnace between carrier and
driveshaft 0.035 0.086 mm (0.001 0.003 in.) 0.12 mm (0.005 in.)
Intermediate shaft contact I.D. 28.015 28.045 mm (1.103 1.104 in.)
Clearance between carrier and
intermediate shaft 0.065 0.111 mm (0.003 0.004 in.) 0.12 mm (0.005 in.)
Carrier bearing starting torque
(preload) For new bearing 2.7 3.9 N·m
(28 40 kgf·cm, 24 35 lbf·in) Adjust
For used bearing 2.5 3.6 N·m (25 37 kgf·cm, 22 32 lbf·in) Adjust
Final driven gear backlash (Reference) 0.086 0.142 mm (0.003 0.006 in.) 0.2 mm (0.008 in.)
A/T differential
pinion gear Backlash 0.05 0.15 mm (0.002 0.006 in.)
I.D. 18.042 18.066 mm (0.7103 0.7113 in.)
Clearance between pinion gear and
pinion shaft 0.055 0.095 mm (0.0022 0.0037 in.) 0.12 mm (0.005 in.)
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ItemMeasurement Qualification Specification
2-21
MANUAL
TRANSMISSION
(5-speed)Type Synchronized, five-speed forward, one reverse
Primary reduction Direct 1:1
Gear ratio 1st 3.267
2nd 1.880
3rd 1.212
4th 0.921
5th 0.738
Reverse 3.583
Final reduction Type Single helical gear Gear ratio 4.839
MANUAL
TRANSMISSION
(6-speed) Type Synchronized, six-speed forward, one reverse
Primary reduction Direct 1:1
Gear ratio 1st 3.267
2nd 2.130
3rd 1.517
4th 1.147
5th 0.921
6th 0.659
Reverse 3.583
Final reduction Type Single helical gear Gear ratio 4.765
AUTOMATIC
TRANSMISSION Type Electronically-controlled automatic, five-speed forward, one
reverse three-element torque converter with lock-up clutch
Primary reduction Direct 1:1
Gear ratio 1st 2.651 2nd 1.516
3rd 1.081
4th 0.772
5th 0.566
Reverse 2.000
Final reduction Type Single helical gear Gear ratio 4.562
STEERING Type Electrical power-assisted rack and pinion Overall ratio 13.62
Turns, lock-to-lock 2.65
Steering wheel diameter 360 mm (14.2 in.)
SUSPENSION Type Front Independent strut with stabilizer, coil spring Rear Independent double wishbone with stabilizer, coil spring
Shock absorber Front and rear Telescopic, hydraulic, nitrogen gas-filled
TIRES Size of front and rear tires (’06-08 models) Except TYPE S P205/55R16 89H
TYPE S P215/45R17 87V
Size of front and rear tires
(’09 model) P215/45R17 87V
Size of spare tire (’06-07 models) Except TYPE S T125/70D15 95M TYPE S T135/80R16 101M
Size of spare tire (’08-09 models) T135/80R16 101M
(cont’d)
08/08/21 14:07:26 61SNR030_020_0021
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Special Tools Required
YES
NO YES
NO
YES
NO
4-6Starting System
Starter System Circuit Troubleshooting
OTC3131
Alternator, Regulator, Battery & Starter tester OTC3131
Available through the Honda Canada Inc. Technical
Tools Department; FAX
866-398-8665/e-mail:
ch_technicaltools ch.honda.com
NOTE:  Air temperature must be within 15 38 °C (59 100 °F) during this procedure.
 After this inspection, you must reset the engine control module (ECM)/powertrain control module
(PCM). Otherwise, the ECM/PCM will continue to stop
the fuel injectors from operating.
 The battery must be in good condition and fully charged.
1. Connect the alternator, regulator, battery & starter tester (OTC3131) to the battery as shown.
NOTE: The probe is not used for battery testing.
2. Do the BATTERY TEST. ThebatteryisOK.Gotostep3.
If the display indicates BAD BATTERY, replace
the battery, then retest. If the display indicates
CHARGE & RETEST, charge the battery, then retest. 3. Connect the Honda Diagnostic System (HDS) to the
data link connector (DLC) (see step 2 on page 11-3).
4. Turn the ignition switch to ON (II).
5. Make sure the HDS communicates with the vehicle and the ECM/PCM. If it does not communicate,
troubleshoot the DLC circuit (see page 11-204).
6. Select ALL INJECTORS STOP in the PGM-FI INSPECTION menu with the HDS.
7. Set the parking brake, then with the shift lever in N or P (A/T model) or the clutch pedal pressed (M/T
model), turn the ignition switch to START (III).
The starting system is OK. Go to step 14.
Go to step 8.
8. Turn the ignition switch to LOCK (0).
9. Check the electrical connections at the battery, the negative battery cable to the body, the engine
ground cables, and the starter for looseness and
corrosion. Then try cranking the engine again.
Repairing the loose connection corrected the
problem. The starting system is OK. Go to step 14.
Based on the following symptoms, take the
appropriate action:
 If the starter does not crank the engine at all, go to step 10.
 If the starter cranks the engine erratically or too slowly,gotostep12.
 If the starter does not disengage from the flywheel ring gear (M/T model) or torque
converter ring gear (A/T model) when you
release the key, replace the starter, or remove
and disassemble it, and check for the following:
– Starter solenoid and switch malfunction
– Dirty drive gear or damaged overrunning clutch
Does the display indicate GOOD or GOOD, LOWCHARGE? Does t he st ar t er cr ank t he engi ne nor mal l y ?
Does t he st ar t er cr ank t he engi ne nor mal l y ?
08/08/21 14:09:22 61SNR030_040_0007
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YES
NO
M/T model
4-84-8 Starting System
Starter System Circuit
Troubleshooting (cont’d)
Clutch Interlock Switch Test
OTC3131 A
B
Terminal
Position
Clutch Interlock Switch
Clutch Interlock Switch 2
1
(PRESSED)
(RELEASED)
12. Do the STARTING TEST with the alternator, regulator battery & starter tester.
NOTE: The probe is used for starter testing.
Go to step 13.
Replace the starter, or remove and
disassemble it, and check for these problems:
 Draginthestarterarmature
 Short in the armature winding
 Excessive drag in the engine
 Open circuit in starter armature commutator segments
 Excessively worn starter brushes
 Open circuit in the starter brushes
 Dirty or damaged helical splines or drive gear
 Faulty overrunning clutch
13. Remove the starter, and inspect its drive gear and the flywheel ring gear (M/T model) or the torque
converter ring gear (A/T model) for damage.
Replace any damaged parts.
14. Select ECM/PCM reset (see page 11-4) in the PGM- FI INSPECTION menu to cancel ALL INJECTORS
STOP with the HDS. 1. Disconnect the clutch interlock switch 2P connector
(A).
2. Remove the clutch interlock switch (B).
3. Check for continuity between the terminals accordingtothetable.
 If the continuity is not as specified, replace the clutch interlock switch (see page 12-8).
 If OK, install the clutch interlock switch, and adjust the pedal height (see page 12-8).
Terminal side of
male terminals
Does the display indicate cranking voltage greatert han or equal t o 8.5 V and t he cur r ent d r aw l esst han or equal t o 380 A?
08/08/21 14:09:23 61SNR030_040_0009
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Overrunning Clutch Inspection Starter Reassembly
4-17
B
A A
B CD
E
F
14. While holding the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive
gear comes out to the other end. If the drive gear
does not move smoothly, replace the gear cover
assembly.
15. While holding the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the
gear shaft does not turn freely, replace the gear
cover assembly.
16. If the drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not
available separately.
Check the condition of the flywheel ring gear (M/T
model), or the torque converter ring gear (A/T
model) to see if the starter drive gear teeth are
damaged. 17. Install the brush into the brush holder, and set the
armature (A) in the brush holder (B).
NOTE: To seat the new brushes, slip a strip of 500
or 600 sandpaper, with the grit side up, between
the commutator and each brush, and smoothly turn
the armature. The contact surface of the brushes
will be sanded to the same contour as the
commutator.
18. While squeezing a spring (C), insert it in the hole on the brush holder, and push it until it bottoms.
Repeat this for the other three springs (D, E, and F).
19. Install the armature and the brush holder assembly into the housing.
NOTE: Make sure the armature stays in the holder.
08/08/21 14:09:28 61SNR030_040_0018
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