Starters - BOSCH: Overhaul: Disassembly
- With starter removed from vehicle, remove dust cover (by removing retaining screws) or remove dust cover band and felt gasket. Lift out brush springs using a wire hook, pull out brushes to 3A of their length. Remove screws connecting field coil terminals to brush boxes.
- Disconnect field coil to solenoid strap, remove hex nut on one side of drive end cover and remove screw. Remove screws securing solenoid and remove solenoid. On mechanical starters, remove collar belt with cotter pin and washer.
- Remove commutator end assembly (must be forced out if made of sheet metal), remove through bolts and pull complete drive end assembly forward. Take all washers off armature shaft, noting their proper location for reassembly.
- If commutator end assembly was removed by unscrewing hex nuts, remove the threaded pins remaining, using hex nut and counter hex nut. Place this unit, consisting of drive end and armature, into a vise, after removing starter housing.
- Remove yoke lever, then from armature shaft, remove cotter pin and left hand threaded castle nut. Remove snap ring using an aluminum or lead-jawed vise (to prevent damage to threads). Discard old snap ring. To prevent damage to bushing in drive end, be sure no burrs are left after removal of ring.
- Remove drive assembly, intermediate bearing with bushing (if equipped) and armature brake, spring plate washer unit or washer spring jaw unit (depending on model).