Section 03-06: Starting System
1994 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY

Starter Motor

NOTE: Although disassembly and service procedures are shown for the starter motor (11002) in this section, it is recommended that the starter motor be returned to Ford Return Parts Center for analysis and review.



Starter Motor—Disassembled View





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

Disassembly

  1. Remove positive brush connector from starter solenoid M-terminal.
  1. Remove starter solenoid retaining screws and starter solenoid (11390) .
  1. Remove through-bolts and separate drive end housing from starter frame and magnet (11075) . Remove seal (11A171) from drive. Remove starter drive and gear assembly from drive end housing.
  1. Remove drive lever and pin (11067) from starter drive (11350) . Remove starter drive stop ring (11222) and stop ring retainer (11223) from output shaft (11355) , then remove starter drive from output shaft . Push E-ring off output shaft , and separate gear assembly from output shaft .
  1. Remove brush plate bolts and brush end plate and bushing (11049) from starter frame and magnet . Remove brush holder (11061) and push starter motor armature (11005) out of starter frame and magnet .
 

Assembly

NOTE: Sealer material meeting Dow formulation Silastic 737 or GE Silicone RTV 123 or equivalent, meeting Ford specification ESA-M4G294-A should be replaced on starter during reassembly.

  1. Install starter motor armature in starter frame and magnet . Apply a thin coating of Syncolube (PTFE) Low Temperature Grease or equivalent, meeting Ford specification ESF-M1C218-A on both ends of armature shaft and spline. Install brush holder while making sure brushes fit over commutator. Apply grease to bushing bore in brush end plate and bushing . Push back grommet onto starter frame and magnet and attach brush end with brush plate bolts. Tighten to 2-3 Nm (18-27 lb-in).
  1. Apply grease to output shaft spline and place stationary gear (11A165) over output shaft . Install armature thrust washer and push E-ring onto output shaft . Place starter drive onto output shaft and install starter drive stop ring and stop ring retainer . Attach drive lever to starter drive .
  1. Grease and install planet gears (11K190) .
  1. Apply grease into drive end housing bushing bore (approximately one-quarter full). Install starter drive gear assembly into housing, making sure to line up bolt holes in gear assembly and housing. Place planet gear retainer (11A167) over gear assembly. Install housing seal into drive end housing.
  1. Position starter frame and magnet to housing and install through-bolts. Tighten to 5-10 Nm (45-89 lb-in).
  1. Position starter solenoid to housing ensuring that solenoid plunger is attached through drive lever (bottom starter solenoid M-terminal should have a metal strip attached to it). Tighten starter solenoid screws to 5-10 Nm (45-89 lb-in).
  1. Attach positive brush connector to starter solenoid (bottom terminal). Tighten nut to 9-14 Nm (80-124 lb-in).
  1. Check that starter motor no-load current draw is within specification. Refer to Component Tests under Diagnosis and Testing.