Disassembling the starter 3S-FE, 4S-FE
1. Disconnect the starter housing assembly with the starter winding from the traction relay.
a) Unscrew the nut and disconnect the wire terminal from the traction relay terminal.
b) Unscrew the 2 tie bolts. Pull the starter housing together with the stator winding out of the traction relay.
c) Remove the felt seal (some models).
2. Disconnect the starter cover from the drive side.
a) Unscrew 2 screws.
b) Remove the starter cover from the drive side together with the idler gear, bearing, overrunning clutch and return spring.
3. Remove the overrunning clutch (3), the idler gear together with the bearing (2) and the spring (4) from the starter cover on the drive side (1).
4. Using a magnetic pin, remove the steel ball from the hole in the overrunning clutch shaft.
5. Remove the brush holder and brushes.
a) Unscrew the two screws and remove the starter cover from the manifold side.
b) Using a screwdriver, press the brush spring and detach the brush from the brush holder. Detach the 4 brushes and remove the brush holder.
6. Disconnect the anchor from the starter housing.
Assembly of starter 3S-FE, 4S-FE
Note: Use high temperature grease to lubricate the bearings and gears when assembling the starter.
1. Apply high temperature grease to the bearings and insert the armature into the starter housing.
2. Install the brush holder.
a) Install the brush holder.
b) Using a screwdriver, bend the brush spring back and install the brush into the brush holder.
Note: Make sure that the (+) brush wires do not come into contact with the ground.
c) Install the starter cover on the collector side and secure it with two screws.
3. Apply grease to the steel ball and insert the ball into the hole of the armature shaft.
4. Install the overrunning clutch, idler gear and starter cover on the drive side.
a) Apply high temperature grease to the return spring, overrunning clutch, idler gear and bearing.
b) Insert the spring into the hole of the traction relay assembly.
c) Install the overrunning clutch (1), idler gear and idler gear bearing (2) into the starter cover on the drive side.
d) Connect the starter cover on the drive side to the traction relay assembly, securing it with two screws.
6. Connect the starter housing assembly with the anchor to the traction relay.
a) Install the felt seal (some models).
b) Align the protrusion on the starter housing with the groove on the traction relay housing.
c) Install 2 tie bolts.
d) Connect the supply wire to terminal "C" of the traction relay.
Starter 3S-FE, 4S-FE.
1 - tie bolt,
2 - brush spring,
3 - brush holder,
4 - cover from the collector side,
5 - housing assembled with stator winding,
6 - bearing,
7 - traction relay,
8 - return spring,
9 - anchor,
10 - bearing,
11 - "parasitic" gear,
12 - overrunning clutch,
13 - bearing,
14 - starter cover on the drive side,
15 - ball,
16 - felt seal (some models).