Section 03-06: Starting System
1993 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY

Starting System

NOTE: Although disassembly and service procedures are shown for the starter motor in this section, it is recommended that the starter motor be returned to Ford Return Parts Center for analysis and review.






Item Part Number Description
1 N805403 Terminal Nut
2 11390 Starter Solenoid
3 11A171 Housing Seal
4 11135 Bushing
5 11130 Drive End Housing
6 N805405 Solenoid Screw (2 Req'd)
7 11002 Starter Motor
8 11067 Drive Lever
9 11350 Starter Drive
10 11223 Stop Ring Retainer
11 11222 Starter Drive Stop Ring
12 — Magnet Retainer (6 Req'd, Part of 11075)
13 11075 Starter Frame and Magnet
14 11061 Brush Holder
15 11059 Brush Spring
16 — Bushing (Part of 11049)
17 11049 Brush End Plate and Bushing
18 N805406 Brush Plate Screw (2 Req'd)
19 N805428 Through-Bolt (2 Req'd)
20 11005 Starter Motor Armature
21 11A172 Armature Thrust Ball
22 11K190 Planet Gear
23 11A165 Stationary Gear
24 N805404 Truarc E-Ring
25 — Magnet Pole Piece (6 Req'd, Part of 11075)
26 — Pole Shunt (6 Req'd, Part of 11075)
27 11036 Pinion Thrust Washer
28 11355 Output Shaft
29 11A167 Planet Gear Retainer
 

Disassembly

  1. Remove positive brush connector from solenoid motor (M) terminal.
  1. Remove solenoid retaining screws and solenoid.
  1. Remove through-bolts and separate drive end housing from starter frame. Remove housing seal assembly from drive. Remove drive and gear assembly from drive end housing.
  1. Remove drive lever from drive assembly. Remove stop ring and retainer from driveshaft, then remove drive assembly from shaft. Push E-ring off driveshaft, and separate gear assembly from driveshaft.
  1. Remove brush plate screws and brush end plate from starter frame. Remove brush assembly and push armature out of frame.
 

Assembly

NOTE: Sealer material (ESA-M4G294-A or equivalent) should be replaced on starter during re-assembly.

  1. Install armature assembly in starter frame. Apply a thin coating of ESF-M1C218-A Grease or equivalent low temperature grease on both ends of armature shaft and spline. Install brush assembly while making sure brushes fit over commutator. Apply grease to bearing bore in brush end plate. Push back grommet onto frame and attach brush end with brush plate screws. Tighten to 2-3 Nm (18-27 lb-in).
  1. Apply grease to driveshaft spline and place stationary gear assembly over driveshaft. Install armature thrust washer and push E-ring onto driveshaft. Place drive assembly onto shaft and install stop ring and retainer. Attach drive lever to drive assembly.
  1. Grease and install planet gears.
  1. Apply grease into drive end housing bearing bore (approximately one-quarter full). Install drive gear assembly into housing, making sure to line up bolt holes in gear assembly and housing. Place gear retainer over gear assembly. Install housing seal assembly into drive end housing.
  1. Position starter frame to housing and install through-bolts. Tighten to 5-10 Nm (45-89 lb-in).
  1. Position solenoid to housing ensuring that solenoid plunger is attached through drive lever (bottom solenoid terminal (M) should have a metal strip attached to it). Tighten solenoid bolts to 5-10 Nm (45-89 lb-in).
  1. Attach positive brush connector to solenoid (bottom terminal). Tighten nut to 9-14 Nm (80-124 lb-in).
  1. Check that starter no-load current draw is within specification. Refer to Bench Tests under Diagnosis and Testing.