Starter disassembly 3S-FE, 4S-FE
1. Disconnect the starter housing assembly with the starter winding from the traction relay.
A) Turn away a nut and disconnect the plug of a wire from an output of the traction relay.
b) Remove the 2 tie bolts. Pull the starter housing complete with the stator winding from the traction relay.
V) Remove the felt seal (some models).
2. Disconnect the drive side starter cover.
A) Loosen 2 screws.
b) Remove the drive end starter cover along with the idle gear, bearing, freewheel and return spring.
3. Remove freewheel (3), idle gear together with bearing (2) and spring (4) from drive side starter cover (1).
4. Using a magnetic pin, remove the steel ball from the hole in the freewheel shaft.
5. Remove the brush holder and brushes.
A) Loosen the two screws and remove the starter cover from the manifold side.
b) Using a screwdriver, depress the brush spring and disconnect the brush from the brush holder. Disconnect 4 brushes and remove the brush holder.
6. Disconnect the anchor from the starter housing.
Starter Assembly 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: check that the wires (+) brushes are not in contact with "weight".
V) Install the starter cover on the manifold side and secure it with two screws.
3. Apply grease to the steel ball and insert the ball into the hole in the armature shaft.
4. Install the freewheel, idler gear, and drive end starter cover.
A) Apply high temperature grease to the return spring, freewheel, idler gear and bearing.
b) Insert the spring into the hole in the traction relay assembly.
V) Install freewheel (1), idle gear and idle gear bearing (2) into the starter cover on the drive side.
G) Connect the drive side starter cover to the traction relay assembly by securing it with two screws.
6. Connect the starter housing assembly with the armature 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.
V) Install 2 tie bolts.
G) Connect lead wire to terminal "WITH" traction relay.
Starter 3S-FE, 4S-FE.
1 - coupling bolt,
2 - brush spring,
3 - brush holder,
4 - cover from the side of the collector,
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 gland (some models).