Starting System & Charging System: Starter: Assembly

1. Apply grease to the shaft sliding surfaces of the internal gear.

   Grease: 

   Multemp #6129 or equivalent

2. Install the internal gear to the shaft.
3. Install the overrunning clutch as follows: 
   1. Apply grease to the spline portion of the shaft.

      Grease: 

      Multemp #6129 or equivalent

   2. Set the overrunning clutch.
   3. Pass a new stopper through, and attach a new snap ring.
   4. Using a press, pressure fit stopper (B) into snap ring (A).
   CAUTION: Do not apply any load to the internal gear.

   Courtesy of SUBARU OF AMERICA, INC.

4. Install the overrunning clutch, internal gear, shaft and shift lever as a single unit to the starter housing.
   NOTE: Apply grease to the moving parts of the shift lever.

   Grease: 

   Multemp #6129 or equivalent

5. Apply grease to the inside of the internal gear and pinion gear, and attach the pinion gear to the internal gear assembly.
   NOTE: Apply grease evenly to the contact surfaces of each gear.

   Grease: 

   Molykote® AG650 or equivalent

6. Install the plate and seal rubber.
7. Set the armature to the yoke.
8. Attach the armature and yoke to the starter housing together as a single unit.
   NOTE: As shown in the figure, match the protrusion of the yoke to the cut out of the starter housing.

   Courtesy of SUBARU OF AMERICA, INC.

9. Use an appropriate tool (suitable attachment, etc.) to attach the brush holder.
   NOTE: Be careful not to damage the brushes.

   Courtesy of SUBARU OF AMERICA, INC.

10. Set the starter cover, and secure the brush holder with bolts.

    Tightening torque: 

    3.4 N.m (0.3 kgf-m, 2.5 ft-lb)

11. Install the through bolt.

    Tightening torque: 

    3.5 N.m (0.4 kgf-m, 2.6 ft-lb)

12. Install the magnet switch.

    Tightening torque: 

    3.4 N.m (0.3 kgf-m, 2.5 ft-lb)

13. Connect the cable to the terminal M.

Tightening torque: 

10.7 N.m (1.1 kgf-m, 7.9 ft-lb)