clutch NISSAN PULSAR 1987 Owner's Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 133 of 238
Manual Transaxle and Drive Shafts 133
Dismantled view of the 1st/2nd gear synchro assembly.
(6) Select a snap ring to obtain the minimum
clearance in the input shaft groove and install the snap
ring to the rear of the input shaft.
NOTE: The maximum allowable clearance
is O.I mm. Snap rings are available from
2.00 mm to 2.30 mm in increments of
.05 mm.
(7) Ensure that the fifth gear end float is within
the specifications. (8) Install the bearing retain er to the front of the
input shaft in the direction noted on removal.
(9) Install the front bearing and spacer to
the input shaft. (10) Select a snap ring to obtain the minimum
clearance in the input shaft groove and install the snap
ring to the front of the input shaft.
NOTE: The maximum allowable clearance
is 0.1 mm. Snap rings are available from
1.27 mm to 1.45 mm in increments of
.06 mm.
(11) Assemble the components of the first/
second and third/fourth sy nchro assemblies aligning
the marks made on dismantling. Ensure that the ends
of the shift plate springs are not aligned.
(12) Install the needle roller bearing and first gear
to the mainshaft.
(13) Install the firs t/second synchro assembly to
the mainshaft. Ensure that the slots in the synchro ring are aligned with the shift plates.
(14) Install the steel ball to the mainshaft
using
grease to retain the ball. (15) Install second gear to the mainshaft and
install
the bush aligning the groove in the bush with the steel
ball. (16) Install third gear to the mainshaft.
(17) Install the third/fourth synchro assembly to
the mainshaft ensuring that the slots in the synchro
ring are aligned with the shift plates.
(18) Install the other steel ball to the mainshaft
using grease to retain the ball. (19) Install the fourth gear bush to the mainshaft
aligning the groove in the bush with the ball. (20) Install the fourth gear to the mainshaft.
(21) Install the fifth gear to the mainshaft.
(22) Install the thrust washer to the mainshaft.
(23) Select C rings to obtain the minimum clear-
ance in the mainshaft grooves and install the C rings to
the mainshaft groove. Install the C ring holder to the
mainshaft.
NOTE: The maximum allowable clearance
is 0.1 mm. C rings are available in thick-
nesses of 3.63 mm to 4.54 mm in incre-
ments of 0.07 mm.
(24) Install the rear and front bearing cones to the
mainshaft using a press and press plates. (25) Ensure that the mainshaft first, second, third
and fourth gear end floats are within the Specifica-
tions.
(26) Temporarily install the differential assembly
to the clutch housing. (27) Install the transaxle case to the clutch
hous-
ing. (28) Tighten the transaxle case retaining bolts to
the specified torque. (29) Install a suitable slotted adaptor into
the
differential pinion shaft a nd, using a torque gauge,
measure the differential tu rning torque. The turning
torque should be in a range from slightly below
3.9 Nm to 7.9 Nm. If the turning torque is not as specified, proceed to
the Differential and Final Drive heading and perform
operations (22) to (29).
If the turning torque is as specified, proceed as
follows:
(30) Remove the transaxle case and install
the
mainshaft to the clutch housing ensuring that the resin
oil channel is located centrally in the end of the
mainshaft. (31) Install the transaxle case to the clutch hous-
ing.
Dismantled view of the 3rd/4th gear synchro
assembly.
Page 134 of 238
134 Manual Transaxle and Drive Shafts
(32) Install and tighten the retaining bolts to
the specified torque.
(33) Repeat operation (29). The total turning
torque should be 5.9-13.7 Nm if new bearings have
been installed or slightly l ess if the original bearings
have been installed. If the turning torque is no t as specified, adjust the
mainshaft turning torque as follows:
(a) Remove the transaxle case rear cover, O ring,
spacer and adjusting shim from the transaxle case.
(b) Ensure that the mainsh aft rear bearing outer
race is fully seated on the bearing cone. (c) Using micrometer depth gauge, measure the
distance from the transaxle case to the bearing outer
race and note the reading. (d) Referring to the following table, select the
appropriate shim, according to the reading noted in
operation (c), required to correct the mainshaft turn-
ing torque.
READING SHIM
2.35-2.40 mm............................................... 0.10 mm
2.40-2.45 mm............................................... 0.15 mm
2.45-2.50 mm...............................................0.20 mm
2.50-2.55 mm...............................................0.25 mm
2.55-2.60 mm...............................................0.30 mm
2.60-2.65 mm............................................... 0.35 mm
2.65-2.70 mm............................................... 0.40 mm
2.70-2.75 mm............................................... 0.45 mm
2.75-2.80 mm............................................... 0.50 mm
2.80-2.85 mm............................................... 0.55 mm
2.85-2.90 mm............................................... 0.60 mm
2.90-2.95 mm............................................... 0.65 mm
2.95-3.00 mm............................................... 0.70 mm
3.00-3.05 mm............................................... 0.75 mm
3.05-3.10 mm............................................... 0.80 mm
3.10-3.15 mm............................................... 0.85 mm
3.15-3.20 mm............................................... 0.90 mm
3.20-3.25 mm............................................... 0.95 mm
3.25-3.30 mm...............................................1.00 mm.
(e) Install the spacer, shim, O ring and rear
cover to the transaxle case. Tighten the retaining
bolts securely.
(34) Measure the total turning torque as previ-
ously described. (35) Install the striking interlock and striking lever
to the clutch housing. (36) Install the striking ro d to the clutch housing
sliding the rod through the lever and interlock. Take
care that the end of the rod does not damage the seal. (37) Install a new retaining pin to the striking rod
using a pin punch. (38) Install the reverse and fifth gear check
assembly to the clutch housing. Tighten the retaining
screws securely. (39) Install the balls, spring and reverse check
plug to the clutch housing ensuring that the smaller
diameter ball enters the hole in the body of the
reverse and fifth gear check assembly body. Apply locking com-
pound and tighten the reverse check plug securely.
(40) Using a bar clamped to the end of the
striking rod, check that a force of 4.9-7.4 Nm is
required to overcome the spring loading of the reverse
and fifth gear check assembly. If necessary, renew the
springs to achieve this correct spring loading.
NOTE: Ensure that the reverse check plug is
coated with locking compound when finally
installed.
(41) Install the shift check ball, spring and plug to
the clutch housing. Ensure that the ball is centrally
located in the plug.
(42) If removed, install the oil reservoir to the
clutch housing.
(43) Install the input shaft assembly and the
reverse idler gear to the clutch housing taking care not
to damage the seal.
(44) Apply locking compound to the bearing
retainer bolts and tighten the bolts to the specified
torque.
(45) Install the spacer to the reverse idler shaft.
(46) Install the differential assembly to the clutch
housing.
(47) Install the mainshaft to the clutch housing
ensuring that the resin oil ch annel is located centrally
in the end of the mainshaft. (48) Install the shift cap to the slot in the first/
second shift fork and install the shift fork and control
bracket to the clutch housing. Use grease to hold the
shift cap in the shift fork slot. Ensure that the reverse
idler shift fork is correctly located over the gear.
(49) Apply locking compound to the threads of
the control bracket retaining bolts and tighten the
bolts to the specified torque. (50) Install the shift cap in the slot in the third/
fourth shift fork and install the fork to the transaxle
assembly. Use grease to hold the shift cap in the shift
fork slot. (51) Install the fifth gear shift fork to the transaxle
ensuring that the shift fork slot engages the control
finger.
(52) Install the fork shaft an d spring to the clutch
housing sliding the shaft through the shift forks. Use
grease to hold the spring in the end of the shaft. (53) Apply a continuous bead of sealant to the
mating face of the clutch housing so that the bead is
located inside the row of bolt holes.
NOTE: Sealant is available from Nissan
spare parts using the part number KP
610-00250.
(54) Install the transaxle case to the clutch hous-
ing. Install and tighten the retaining bolts to the
specified torque. (55) Select each gear in turn and check that the
transaxle turns freely in each gear. Ensure that it is not
Page 136 of 238
136 Manual Transaxle and Drive Shafts
right hand side gear and the adjacent spacer in an area
where there is no oil groove in the differential case.
(d) Insert another 0.03 mm feeler gauge diago-
nally opposite the first feeler gauge to avoid tilting the
side gear.
(e) Insert a splined adaptor into the right hand
side gear and attempt to rotate the gear by hand.
(f) If the gear cannot be rotated, change the
thickness of the left hand side gear spacer, repeating
the test until the gear can be rotated.
NOTE: Spacers are available in thicknesses
from 0.8 mm to 1.5 mm in increments of
0.1 mm.
(g) Remove the 0.03 mm feel er gauges and insert
0.09 mm feeler gauges to the same position. The gear
should lock.
(h) The spacer selection is correct when the right
hand side gear can be rotated with 0.03 mm feeler
gauges inserted but locks when 0.09 mm feeler gauges
are inserted.
(18) Install the ring gear to the differential case
with the chamfered edge of the ring gear inwards. (19) Install and tighten the retaining bolts in
a
diagonal sequence to the specified torque.
(20) Install a new speedometer drive gear to
the
differential case. Install the stopper adjacent to the
drive gear.
(21) Install the differentia] carrier bearing
cones
and roller assemblies to the differential case.
(22) Remove the adjusting shim from behind the
carrier bearing outer race in the transaxle case and
replace the outer race in the transaxle case.
(23) Install the differential assembly to the clutch
housing. (24) Install the transaxle case to the clutch housing
and tighten the retaining bolts to the specified torque.
(25) Mount a dial gauge to the clutch housing so
that the contact point is resting on the differential
case. (26) Insert a bar through the opposite side gear
and, contacting the pinion shaft, raise and lower the
differential case and measure the end float in the
carrier bearings. (27) Using the following table, select a shim to
correspond to the relevant end float.
END FLOAT SHIM THICKNESS
0.30-0.34 mm....................................................0.64 mm
0.34-0.38 mm................................................... 0.68 mm
0.38-0.42 mm................................................... 0.72 mm
0.42-0.46 mm................................................... 0.76 mm
0.46-0.50 mm................................................... 0.80 mm
0.50-0.54 mm................................................... 0.84 mm
0.54-0.58 mm................................................... 0.88 mm
0.58-0.62 mm................................................... 0.92 mm
0.62-0.66 mm................................................... 0.96 mm
0.66-0.70 mm................................................... 1.00 mm
0.70-0.74 mm................................................... 1.04 mm
0.74-0.78 mm ................................................... 1.08 mm
0.78-0.82 mm ................................................... 1.12 mm
0.82-0.86 mm ................................................... 1.16 mm
0.86-0.90 mm ................................................... 1.20 mm
0.90-0.94 mm ................................................... 1.24 mm
0.94-0.98 mm ................................................... 1.28 mm
0.98-1.02 mm ................................................... 1.32 mm
1.02-1.06 mm ................................................... 1.36 mm
1.06-1.10 mm ................................................... 1.40 mm
1.10-1.14 mm ................................................... 1.44 mm
1.14-1.18 mm ................................................... 1.48 mm
1.18-1.22 mm ................................................... 1.52 mm
1.22-1.26 mm ................................................... 1.56 mm
1.26-1.30 mm ................................................... 1.60 mm
1.30-1.34 mm ................................................... 1.64 mm
1.34-1.38 mm ................................................... 1.68 mm
1.38-1.42 mm ................................................... 1.72 mm
1.42-1.46 mm ................................................... 1.76 mm
The thickest shim available is 0.88 mm. Multiple
shims are required above this thickness.
(28) Install the shim behind the carrier
bearing
outer race in the transaxle case and assemble the unit
once more. (29) Using a suitable slotted adaptor engage the
pinion shaft and using a to rque gauge, measure the
differential turning torque. The turning torque when new carrier bearings
have been installed should be 3.9-7.8 Nm or slightly
lower if the original carrier bearings have been
replaced.
(30) Assemble the transaxle and measure the total
turning torque of the diff erential assembly and the
mainshaft. The total turning torque should be 5.9 to
13.7 Nm with new bearings or slightly lower if the
original bearings have been replaced.
5. GEAR LEVER ASSEMBLY
TO DISMANTLE AND ASSEMBLE
(1) Remove the gear lever knob and remove the
centre console as described in the Body section. If not
previously removed, remove the rubber boot sur-
rounding the gear lever. (2) Raise the front of the vehicle and support it
on chassis stands. Remove the catalytic converter and
heat shield as described in the Engine section.
(3) Remove the bolt and disconnect the control
rod from the bottom of the gear lever, noting the
position of the return spring and bracket.
(4) Remove the nuts retaining the gear lever
socket to the support rod. (5) Working inside the vehicle, lift the gear lever
out of the floor bracket. (6) Separate the lower rubber boot, socket,
spring seat, spring, upper ball seat and lower ball seat
from the gear lever, noting the location of each
component to aid assembly.
Page 142 of 238
142 Automatic Transaxle
(8) Install the dipstick and start the engine and
recheck the fluid level.
NOTE; Do not overfill the transaxle or
foaming and unsatisfactory operation of the
transaxle will result.
TO DRAIN AND REFILL
This is not a normal maintenance and lubrication
procedure. It is only necessary to drain the complete
system, including the torq ue converter and the oil
cooler, when the transaxle assembly is removed for
overhaul or the renewal of transaxle components such
as bearings, clutches or as semblies. When this condi-
tion arises, the torque converter and the cooler should
be cleaned and flushed to remove any dirt or sludge.
After transaxle overhaul, install approximately 6
liters of new transaxle fluid, and top up as previously
described.
4. BRAKE BAND
Band adjustment is not a normal maintenance
procedure.
The adjustment entails removal of the valve body
and for this reason the vehicle should be taken to an
authorized dealer.
5. KICKDOWN CABLE
TO ADJUST
(1) On models with a 1.6 liter engine, remove
the air cleaner assembly. (2) With the aid of an assistant, ensure that the
throttle valve is fully open when the throttle pedal is
fully depressed. (3) Push the clip on the outer kickdown cable
and pull the cable away from the throttle linkage.
View of the kickdown cable adjustment point. 1.6 liter
engine.
(4) Slowly depress the throttle pedal to the full
throttle position.
The outer kickdown cable will automatically ad-
just and emit a clicking noise.
6. TRANSAXLE SELECTOR LINKAGE
TO ADJUST CONTROL CABLE
(1) Place the selector lever in the Park position.
(2) Loosen the control cable locknuts and ensure
that the transaxle selector lever is in the Park position.
View of the transaxle selector linkage control cable
adjustment.
(3) Hold the selector rod horizontal and adjust
the outer locknut until it touches the selector rod.
(4) Tighten the inner locknut securely.
7. NEUTRAL SAFETY SWITCH
The neutral safety switch, incorporating the re-
verse lamp switch is located on the transaxle case
View of the kickdown cable adjustment point. The
arrow indicates the direction in which the outer kick-
down cable must be pulled to initiate the automatic adjustment. 1.8 liter engine.
Page 190 of 238
190
ELECTRICAL SYSTEM
CAUTION: To prevent severe electrical shock extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.
SPECIFICATIONS
BATTERY
Type ..................................................12 volt lead acid
Polarity to earth .................................... Negative ( - )
Specific gravity:
Fully charged ................................... A bove 1.250
Fully discharged ................................Below 1.130
ALTERNATOR
Make .................................................Bosch or Hitachi
Maximum output .......................................... 70 amps
Polarity to earth .................................... Negative ( - )
Stator windings ......................................... Star wound
Regulator type ................................................ Integral
Brush length minimum:
Bosch ........................................................ 5.0 mm
Hitachi ............................. 6.0 mm or limit mark
STARTER MOTOR
Make .................................................Hitach i or Bosch
Type ............................ 4 pole 4 brush reduction gear
Operation control.................................. Solenoid and
overrunning clutch
Undercut of commutator (maximum):
Hitachi ...................................................... 0.8 mm
Brush length (minimum):
Bosch ........................................................ 8.0 mm
Hitachi ........................................................11 mm
Brush spring tension;
Hitachi ............................................... 15.7-19.6 N
Hitachi:
Drive pinion stopper clearance ........ 0.3-1.5 mm
Selective fit adjuster plates ........ 0.5 and 0.8 mm
IGNITION SYSTEM
The ignition system is an integral part of the
engine management system. The Specifications, testing
and overhaul procedures are fully covered in the Fuel
and Engine Management section.
TORQUE WRENCH SETTINGS
Alternator pulley retaining nut:
Bosch ......................................................... 50 Nm
Hitachi ....................................................... 59 Nm
1. BATTERY AND CHARGING SYSTEM
TROUBLE SHOOTING
BATTERY UNDERCHARGED
3. Loose or broken drive belt: Adjust or renew
the drive belt. 4. Faulty alternator regulator; Renew the regu-
lator unit.
5. Faulty battery: Install a new battery of
the
recommended type and capacity. 6. Faulty alternator: Overhaul or renew the
alternator. 7. Fault in the charging circuit wiring: Check
and repair or renew the wiring harness. 8. Faulty connections in the charging circuit:
Check and repair the connections. 9. Fusible link blown; Rectify the fault and
renew as necessary.
NOTE: Check the state of charge (specific
gravity) of the battery- as described under
the
Battery heading in this section. If the battery
is undercharged, check the possible causes in
the order given.
BATTERY OVERCHARGED
• Faulty alternator regulator unit:
Renew the
regulator unit.
• Faulty alternator: Overhaul or
renew the
alternator. • Faulty charging circuit wiring or
connec-
tions: Check and renew or repair the faulty
compo-
nents.
NOTE: An overcharged battery is indicated
by continual loss of water through boiling.
Page 201 of 238
Electrical System 201
nosed pliers. This will safeguard the diodes
by transferring any excess heat to the jaws of
the pliers.
Using a suitable drift, install the bearing into
the drive end bracket, install the retainer plate and
screws. Tighten the screws securely. Using a suitable press and press plates, install
the bearing to the slip ring end of the rotor shaft.
Ensure that pressure is ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft rear bearing stop
ring is positioned so that the protruding part of the
ring is located in the deepest part of the groove. Install the stator, diode pack and
regulator
assembly to the slip ring e nd bracket. Install the
retaining nuts and washers and tighten securely. Install the nut and insulator to the terminal
and tighten securely. Using a piece of wire, hold the brushes in a
retracted position. Hold the drive end bracket in a soft jawed
vice and install the rotor shaft assembly to the drive
end bracket. Install the pulley, retaining nut and washer to
the rotor shaft and tighten the retaining nut to the
specified torque. Apply a heated 200 watt soldering iron to the
slip ring end bracket at the bearing mounting boss for
3-4 minutes to heat the bracket and allow the
installation of the rotor shaft rear bearing. Aligning the marks made on dismantling and
ensuring that the rotor sh aft rear bearing retaining
ring protrusion is located in the deepest part of its
groove, install the rotor/stator assembly to the slip ring
end bracket.
Remove the brush retr acting wire from the
alternator, ensure that the alternator component
marks are aligned, install the retaining through bolts
and tighten them securely. Check the alternator rotor for smooth oper-
ation and install the al ternator to the vehicle
as
previously described.
Check the alternator operation on the vehicle
as previously described.
8. STARTER MOTOR
Special Equipment Required:
To Renew Brushes — Soldering iron
To Renew Armature Bearings — Bearing puller
DESCRIPTION
Two types of starter motors are installed to the
range of vehicles covere d by this manual, either
Hitachi or Bosch.
The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.
A solenoid switch is attached to the starter drive
end bracket. The solenoid plunger is connected to
the overrunning clutch and drive pinion assembly
through a lever and pivot arrangement.
When the solenoid windings are energized, the
plunger acting on the lever and pivot engages the drive
pinion with the flywheel ri ng gear and at the same
time closes the switch supplying power from the
positive lead of the battery to the starter motor field
coils and armature to operate the motor.
As the engine fires, the over-running clutch of the
drive pinion assembly prevents high speed rotation of.
and possible damage to, the starter armature if the
solenoid windings are not immediately de-energized
by releasing the ignition key.
The starter solenoid switch windings are energized
by the ignition switch.
TO TEST ON VEHICLE
Should the starter motor fail to operate when the
ignition switch is turned to the Start position, check
the following points:
Check the battery condition and state of
charge. Refer to the Battery heading for the correct
procedure.
Clean the battery terminals, taking particular
care to remove the scale from the positive ( + )
terminal post and terminal. Check the earth connection for tightness and
cleanliness.
Switch on the headlamps and turn the igni-
tion switch to Start. If the lamps dim but the starter
motor does not operate, it could indicate that a short
circuit has developed in the starting system. Check that the engine is not seized or that the
starter motor drive pinion and ring gear are not
locked as these conditions would -give the same
indications as above.
(5) If the lamps do not dim and the starter
motor does not operate, this would indicate an open
circuit such as a broken or disconnected wire or a
switch not operating.
If the vehicle is equipped with an automatic
transaxle, turn the ignition switch to Start and move
the selector lever through all the gear selection range.
If the starter motor operates in any position other
than N or P, the neutral safety switch is faulty.
(6) Check all the external wiring to ensure that
the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
starter motor, the unit will have to be removed and
tested.
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Disconnect the wiring from the starter motor
solenoid. Remove the starter motor mounting bolts,
Page 202 of 238
202 Electrical System
View of the Bosch starter motor removed from the
vehicle.
noting the position of the earth cable, and maneuver
the starter motor out of the engine compartment.
Installation is a reversal of the removal procedure
with attention to the following points:
Replace the earth cable to the position noted
on removal.
Tighten the starter motor mounting bolts
securely.
HITACHI STARTER MOTOR
To Dismantle
Remove the starter motor from the vehicle
as previously described. Mount the starter motor upright in a soft
jawed vice gripping the drive end bracket. Loosen the solenoid field coil terminal nut
and disconnect the cable from the solenoid.
Scribe a line across the drive end bracket,
yoke and end cover to facilitate correct alignment
during assembly. Remove the bolts retaining the end cover
and yoke to the drive end bracket and remove the end
cover from the yoke. Remove the yoke, armature and brush
holder as an assembly from the drive end bracket.
Note the position of the O ring sealing the yoke. Release the brush spri ngs and separate the
brushes from the brush holder. Remove the brush holder from the yoke.
Separate the armature from the yoke.
Scribe a line across the solenoid and the
drive end bracket to facilitate correct alignment
during assembly. Remove the solenoid retaining bolts and lift
the solenoid, spring, lever an d rubber seal out of the
drive end bracket. Note the installed position of the
components. Mount the drive end bracket in the vice with
the pinion uppermost and Remove the screws retaining
the pinion housing to the drive end bracket. Remove the pinion housing from the drive
end bracket,
Remove the pinion assembly from the drive
end bracket, Mount the pinion in the vice, hold the collar
down and remove the snap ring from the end of the
pinion. Remove the collar and spring from the
pinion and slide the pinion out of the clutch assembly. If necessary, prise the bearings off the clutch
assembly using two screwdri vers. Note the location of
the larger bearing. If necessary, remove the bearings from the
armature using a bearing puller.
To Check and Inspect
Clean all the starter motor components thor-
oughly but do not immerse the yoke, armature or
clutch assembly in cleaning solvent.
Check the brush holder insulation using an
ohmmeter. Connect one test probe to the brush holder
positive side and the other test probe to the negative
side. If continuity exists , renew the brush holder.
Check the brushes for adequate length. Re-
new the brushes if they are worn to less than the
length listed in Specifications. The brushes should be
a free sliding fit in the brush holders. Check the brush
springs for adequate tension.
Check the field coil continuity using an
ohmmeter. Connect one test probe to the positive
brush and the other test probe to the solenoid cable
terminal. If continuity does not exist, renew the field
coils.
View of the Hitachi starter motor removed from the
vehicle
.
Page 203 of 238
Electrical System 203
BRUSH HOLDER
Dismantled view of the Hitachi starter motor.
Check the field coil insulation using an
ohmmeter. Connect one test probe to the solenoid
cable terminal and the other test probe to the body of
the yoke. If continuity exists, renew the field coils. Check that the commutator is free from
pitting and burning. Clean the commutator with a
petrol moistened cloth and polish with a strip of fine
glass paper.
A badly worn commutator may be repaired by
mounting in a lathe and taking a light cut using a very
sharp tool with the lathe rotating at high speed. After
machining, undercut the insulation between the seg-
ments to Specifications. Do not machine the commu-
tator to below 29 mm diameter. Check the armature
gear teeth for wear and damage.
Check the armature for short circuit using an
ohmmeter. Place one of the test probes on the
armature shaft or core and move the other test probe
around the periphery of the commutator. If continuity
exists at any point, the armature is faulty and should
be renewed. Check the pinion for wear and damage. The
pinion should move smoothl y along the clutch assem-
bly helical splines. Check the spring, collar and snap
ring for serviceability.
Check that the clutch assembly locks in one
direction and rotates smoothly in the opposite direc-
tion. Check for wear and damage to the reduction gear
teeth on the outside of the clutch assembly.
Check that continuity exists between the
solenoid spade terminal and the solenoid body and
between the solenoid spade terminal and the solenoid
field coil terminal. Renew the solenoid if continuity
does not exist. Renew all the components found to be
unserviceable in the above checks.
To Assemble
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) If removed, install new bearings to the clutch
assembly and the armature. Lubricate the armature
bearings with high temperature grease.
The sealed bearings on the clutch assembly are
lubricated during manufacture and further lubrication
is unnecessary.
Apply high temperature grease to the yoke
end cover bearing recess, the drive end bracket and
pinion housing bearing recesses, the clutch assembly
reduction gear teeth, the armature gear teeth, the
pinion helical splines, th e solenoid plunger and the
spring and lever. Install the pinion to the clutch assembly and
install the spring and collar to the pinion. Hold the collar down and install the snap ring
to the end of the pinion.
Position the collar over the snap ring. If
necessary, squeeze the snap ring into the groove using
multigrip pliers to enable the collar to be clipped over
the snap ring. Install the pinion and clutch assembly to the
drive end bracket.
Install the pinion housing to the drive end
bracket. Install and tighten the retaining screws
se-
curely. Check that the pinion rotates freely.
Assemble the lever and spring to the solenoid
in the position noted on dismantling.
Install the solenoid assembly and rubber seal
to the drive end bracket.
Install and tighten the solenoid retaining
bolts securely. Connect 12 volts between the solenoid spade
terminal and the solenoid field coil terminal and
measure the distance that the end of the pinion
protrudes from the pinion housing. Pull the pinion by hand until it contacts the stop
and measure the pinion end protrusion.
If necessary, add or subt ract shims between the
solenoid mounting face and the drive end bracket
until the difference between the above measurements
is 0.3-1.5 mm.
Install the armature to the yoke.
Install the brush holder to the yoke. Install
the
PLUNGER
O RING
Page 205 of 238
Electrical System 205
Dismantled view of the brush holder assembly. Bosch
starter motor.
side and the other lead to the negative side. If there is
any indication of leakage the ohmmeter will show a
reading other than infinity. Repair or renew the brush
holder if leakage is evident.
(2) Check the brushes for adequate length.
Brushes should be renewed when their length is below
Specifications. They should be a free sliding fit in the
brush holders.
NOTE: Due to the difficulty involved in
removing and installing the brushes in the
Bosch starter motor, it is recommended that
the brush holder be renewed as an assembly.
(3) Check that the commutator is free from
pitting and burning. Clean with a petrol moistened
cloth and polish with a strip of fine glass paper.
A badly worn commutator may be repaired by
mounting in a lathe, spi nning at high speed, and
taking a light cut with a very sharp tool. After turning,
undercut the insulation between the segments.
(4) Check the armature for short circuit using an
ohmmeter.
Place one of the test lead s on the armature shaft
or core and move the other lead around the circum-
ference of the commutator. If the ohmmeter shows a
reading at any point the armature is faulty and should
be renewed.
Check the drive assembly clutch pinion teeth
for wear, scoring or chipping. A clutch in good
condition should take up the drive in one direction
only. It should rotate easily and smoothly in the
non-drive direction and the assembly should move
smoothly along the armature or drive shaft helical
splines.
Check the armature shaft bushes for wear
and renew as necessary. The old bushes must be
removed and the new ones pressed into the end
brackets using a polished mandrel of the exact diam-
eter of the armature shaft. NOTE: The new bushes must not be reamed
to size, as reaming will impair the porosity
of the bushes and cause early failure. New
bushes should be allowed to stand immersed
in clean light engine oil for one hour before
installation.
To Assemble
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
Lubricate the helix of the drive shaft lightly
with graphite grease and install the drive assembly
to
the drive shaft. Install the stop collar and snap ring, slide the
stop collar over the snap ring to lock the snap ring in
position.
Lubricate the bushes in both end brackets
sparingly with engine oil. Install the engaging lever and gear set into the
drive end bracket. Install the centre rear bracket and the engag-
ing lever seal into the drive end bracket.
Slide the brush holder assembly into position
on the commutator ensuring that the brush holders
are correctly positioned in the anchor points. Install the commutator end bracket to
the
armature, install the shims and C clip. Check that the armature end float is satisfac-
tory and adjust as necessary using shims of the correct
thickness.
Align the slot in the commutator end bracket
with the cut out on the wiring seal and install the
armature end cover to the commutator end bracket.
Install the cover retaini ng screws but do not tighten.
Ensure that the permanent magnets in the
yoke have not picked up any debris and slide the yoke
over the armature ensuring that the wiring seal locates
correctly in the slot in the yoke.
View showing the planetary gear set. Bosch starter
motor.