Note: Depending on the malfunction that has occurred, the sequence and scope of repair work may be changed.
The most common starter faults:
1. The winding burns out or the contact bolts and contact plate in the traction relay burn out. To eliminate these faults, it is necessary to replace the traction relay. This can be done on a car without removing the starter.
2. The overrunning clutch of the drive is faulty. To eliminate this malfunction, it is necessary to disassemble the starter and replace the drive.
3. The starter brushes are worn out. The starter should be removed, the brush assembly replaced and the commutator cleaned. When replacing the brush assembly, there is no need to remove the starter drive and traction relay.
To complete the work you will need:
- two power wires (with clamps on the ends) to start the engine from the battery of another car;
- external snap ring pliers;
- ohmmeter.
Examination
Note: You can check the electrical part of the starter without disassembling it.
1. Remove the starter (see above, "Starter - removal and installation").
Warning: When performing the test, do not short-circuit the positive battery terminal wire clamp to the starter housing. To do this, the clamp should be extended, 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 armature starts to rotate, the starter motor is good.
3. Connect the second wire to contact bolt 1 of the traction relay. Using a screwdriver or other suitable metal object, we short-circuit terminal 3 and the contact bolt of the traction relay. If you hear a loud click and the starter armature starts to rotate, then 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) traction relay.
2. Remove the wire tip from the contact bolt of the traction relay.
3. Using an 8 mm socket wrench, 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 all the way in, make sure that the contact bolts close (electrical resistance is close to zero). The faulty traction 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 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 gear. The needle bearings of the satellite gears must not be damaged. The gear teeth of the gearbox should not have any chips, burrs, traces of corrosion or other damage. It is necessary to replace the faulty gearbox elements (either the drive or the starter assembly).
9. Using a screwdriver to press against the top of the starter front cover, 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 must move freely along the shaft splines without jamming. The drive gear must rotate freely in one direction only; chipped teeth and strong nicks on the leading part of the teeth are unacceptable. Minor defects can be removed with a diamond file or an abrasive stone. It is necessary to replace the faulty and badly 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 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 washer 2 from drive 4, coupling 5 together with drive lever 3.
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 drive shaft 1, sequentially remove thrust washer 5, shaft support 4, sealing rubber ring 3 and outer gear of 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.
Traces of charring of the windings are not allowed - such an anchor must be replaced.
25. Clean the dirty collector with fine-grained sandpaper, clamping the armature shaft through a strip of thick paper in the chuck of an electric drill. We wash the anchor with water and detergent to remove dirt, coal dust and abrasive residues and carefully wipe dry with a clean rag, blow it 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 with 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, we put 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, use pliers to bend the four spring stops. We install the remaining three springs in the same way;
- 7) insert the starter anchor into the stator with the brush assembly and rear cover put 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 carried out in the reverse order of disassembly. At the same time, we apply SHRUS-4 grease to the gearbox parts. Before installing the drive, we dip it in engine oil and let the oil drain. The bushings in which the anchor and drive shafts rotate, as well as the drive screw splines, 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 (see p. 161).