Repair and Diagnosis: Electrical: Starter: Overhaul: Disassembly

1. Clamp starter in vise. Remove nut and washer from solenoid main terminal connection. Remove solenoid retaining screws and unhook solenoid plunger.
2. Remove screws and end cap with rubber seal from commutator end housing. Wipe grease from armature shaft and remove "C" clip with shims.
3. Remove bolts or nuts from studs and lift off commutator end housing. Lift springs clear of brushes and slide brushes from holders. Remove brush plate from housing.
4. Separate drive end housing and armature assembly from yoke by tapping apart. Remove armature assembly from drive end housing while at the same time uncoupling actuating arm.
5. To remove actuating arm, remove rubber insert from drive end housing. Remove pivot arm screw and nut and extract actuating arm.
6. To remove drive pinion assembly from armature shaft, separate thrust collar from over "C" clip. Remove "C" clip from its groove and drive pinion assembly off armature shaft.

Fig 1: Exploded View of Typical Bosch Starter