STARTER MOTOR Removal and Installation

First, disconnect the battery. Remove the nut from the terminal on the end of the starter motor and disconnect the starter cable. Remove the two bolts (lower one first) retaining the starter motor to the engine and withdraw the starter motor from its location. Install the starter motor in the reverse order of removing. The starter motor may be either a Lucas M35G or a M35J type, the latter being a later fitment. Although externally similar, apart from the brush cover band on the M35G type, they differ mainly in two respects. The M35G type has a peripheral contact commutator on which the brushes bear from the side, whereas the M35J has a facetype commutator where the brushes bear on the end face. In the M35J unit, the field windings are earthed to the starter yoke but the brush box assembly and the commutator end plate brushes are fully insulated. The end terminal post is connected directly to the end plate brushes. The M35G field windings are insulated from the yoke and incorporate the field terminal post, but the end plate brushes are earthed directly to the end plate. Brushes - M35G Starter A good indication of the brush condition can be obtained by inspecting the brushes through the apertures in the starter body, after sliding away the cover band. If the brushes are damaged or worn so that they no longer make good contact on the commutator, they should be renewed as a set. The brushes can be further inspected by lifting the brush springs, using a piece of hooked wire, and withdrawing them from their holders on the commutator end plate. If the brushes are to be replaced, remove the nuts, washers and insulation bush from the field terminal post at the end plate. Unscrew the two through-bolts and withdraw the end plate from the starter body. Inspect the contact surface on the outside of the commutator or any signs of wear, burning or other damage. If the surface is blackened or dirty, it should be wiped clean with a petrol-moistened cloth. Slight imperfections can be removed with fine glass paper, but emery cloth or similar abrasive must not be used. If the commutator is grooved, scored or badly worn, it should be skimmed or replaced. To renew the earthed brushes on the commutator end plate, unsolder the flexible lead from the terminal eyelet adjacent to the brush holder. Open the eyelet, then insert the replacement brush lead, squeeze the eyelet closed and resolder the connection. To renew the insulated brushes on the field coils, cut the existing brush leads approximately 1/4 in (6 mm) from the field coil connection. Clean the ends of the copper leads still attached to the field coils and solder the new brush leads to them. Note that the insulated brushes have longer leads then the earthed brushes, and also have a braided covering. Check the new brushes for freedom of movement in their respective holders. Ease them if necessary by cleaning both the brushes and holders with a petrol-moistened cloth, or by polishing the sides of the brushes lightly with a fine file. Check that the insulator band is fitted between the starter body and the end of the field coils, and that the insulating bush for the field terminal post is also fitted to the commutator end plate. Also check that the thrust washer is in place in the end of the armature shaft. Pass the field brushes out through the apertures in the starter body. Fit the earthed brushes in their respective holders in the end plate and locate the brush springs on the side of each brush to hold them in the raised position. Assemble the end plate to the starter body, ensuring that the locating dowel on the plate correctly engages the notch in the yoke. Fit the through-bolts and tighten securely. Assemble the insulation bush, washers and nuts on the field terminal post. lift the brush springs and fit the field brushes into their respective holders. Press the brushes down into the commutator, then lift the brush springs into position on top of the brushes. Refit the brush cover band over the brush apertures and tighten the clamp screw to secure. Brushes - M35J Starter In this case the commutator end plate must be removed to allow inspection of the brushes as inspection apertures are not provided. Remove the two retaining screws and withdraw the commutator end plate from the starter yoke. Withdraw the two field brushes from the brush box on the end plate and separate the end plate from the yoke. Inspect the brushes for wear or damage. Brushes which are worn to, or are approaching the wear limit of 3/8 in (10 mm) must be renewed as a set. Inspect the contact surface on the end of the commutator for any signs of scoring, burning or other damage. If the surface is grooved or badly scored, the commutator should be skimmed or replaced. If the surface is merely blackened or dirty it can be cleaned with a petrol-moistened cloth, or fine glass paper, but emery cloth or similar abrasive must not be used for this purpose. If the brushes on the commutator end plate are to be renewed, these are supplied attached to a new terminal post. Withdraw both brushes from their holders, then remove the nuts, washers and insulation sleeve from the terminal post and withdraw the terminal post and remove the insulation piece. Install the new brushes and terminal post in the reverse order of removing. Ensure that the insulation piece and sleeve are correctly located. Retain the longer brush lead under the clip on the end plate. If the field winding brushes are to be renewed, these are supplied attached to a common lead. Cut the old brush leads approximately 1/4 in (6 mm) from their joint on the field windings. Clean the leads still attached to the joint and solder the common lead of the new brushes to them. Do not attempt to solder directly to the field winding strip as this may be made of aluminium. Check the brushes for freedom of movement in their respective holders. Any brushes which are stiff should be cleaned with a petrol-moistened cloth, or eased by lightly polishing the sides of the brush with a fine file. Install the two commutator end brushes and the two filed winding brushes in their respective holders on the brush box. Check that the thrust washer is in position on the end of the armature shaft, then assemble the commutator end plate to the starter yoke. Secure the end plate with the two retaining screws. Drive Pinion If difficulty is experienced with the starter motor pinion not meshing correctly with the flywheel ring gear, it may be that the drive assembly requires cleaning. The pinion and barrel assembly should move freely on the screwed sleeve. If there is dirt or other foreign matter on the sleeve it should be washed off with paraffin. Do not use grease or oil on the drive assembly as this would attract dirt. To replace the drive pinion assembly, compress the main drive spring using a suitable clamping device (e.g. Bendix Spring Compressor Tool) and remove the jump ring from its groove at the end of the armature shaft. Release the clamping device and remove the spring cup, drive spring, thrust washer and drive pinion assembly from the shaft. It may be necessary to depress the pinion assembly and turn it slightly to disengage it from the shaft splines. It should be noted that, if the screwed sleeve is worn or damaged, it is essential that it is renewed together with the barrel and pinion. Fit the new pinion assembly on the armature shaft, with the pinion teeth towards the starter body. Assemble the thrust washer, drive spring and spring seat on the shaft, compress the drive spring and fit the jump ring. Ensure that the ring is correctly seated in the shaft groove once the spring is released.