Repair and Diagnosis: Electrical: Starter: Starters: Overhaul: Reassembly

Make sure shift fork plates have approximately 1/16" side movement, lubricate sparingly between plates with SAE 10 engine oil. Position shift fork in housing bending one tip of pin at 15° angle away from housing. Fork and pin must operate freely. Install solenoid moving core and engage shifting fork.
Start pinion shaft into drive housing. Install friction washer, drive gear, clutch and pinion assembly, thrust washer, retaining ring and thrust washer. Complete installation of pinion shaft, making sure shifting fork properly engages clutch actuators. The friction washer must be positioned on shoulder of splines of pinion shaft before driven gear is positioned. Install driven gear snap ring, pinion shaft "C" clip, and starter solenoid return spring (into bore of movable core).
Inspect starter solenoid switch contacting washer for burned condition, reversing washer if necessary. Install solenoid contact plunger assembly into solenoid. Make sure contact spring is positioned on shaft of solenoid contact plunger assembly. Place battery terminal stud in brush holder. Inspect condition of contacts in brush holder plate. Replace brush holder with brushes and contacts as an assembly if burned. Position seal on brush holder plate.
Start solenoid lead wire through hole in brush holder, install solenoid stud, insulating washer, flat washer and nut. Wrap lead wire tightly around brush terminal post, solder with high temperature resin core solder and resin flux. Install brush holder to solenoid attaching screws. Enter solenoid coil and brush plate assembly into starter gear housing, install and tighten attaching nuts.
Position brushes with armature thrust washer, so brushes rest on washer tabs. Washer will hold brushes out and facilitate armature installation. Install brush terminal screw.
Position field frame in correct position on gear housing and install armature in field frame and gear housing. Carefully engage splines of shaft with reduction gear by rotating armature slightly. Install thrust washer on armature shaft. Position starter end head assembly and tighten through bolts securely.