(4) Install the drive assembly and yoke shift lever. Put the yoke cover
in place and install the yoke pin for proper shift lever pivoting. Secure the yoke
cover, observing that all seals and packing are in place.
(5) During installation of the solenoid relay there is a rubber boot
that must be on the inside of the yoke cover and over the outside edge of the
solenoid case for proper seal. Do not install inspection plug and gasket until
final tests and adjustments are completed.
(6) Include the thrust washer during pinion housing installation. Next
aline the scribe marks on the pinion housing and intermediate housing. Torque
tighten screws to 100 pound-inches.
g. Pinion clearance adjustments. The drive assembly is adjusted for proper
shifting within the pinion drive housing. The clearance between the thrust washer
and pinion is to be from 0.020 to 0.050 inch when the solenoid is energized (fig
(1) To make this adjustment the starter motor is made inactive by
disconnecting the field terminal and ground terminal on the starter frame.
(2) The solenoid is energized with a 24-volt battery. The pinion will
move forward; therefore, before making the measurement, push the pinion back toward
the armature to take up the slack movement.
h. Pinion block test. The pinion block test is a test of continuity of the
solenoid relay. This controls the point of pinion travel and the application of
current to the starter motor. For pinion travel of greater than 0.500 inch from
the thrust washer, the solenoid contacts should be open; for less than 0.500 inch,
the contacts will be closed, thereby applying current to the motor if it is
(1) This distance is checked with a series of spacer blocks or thrust
washers and a continuity tester. Figure 31 shows the spacer block between the
pinion and thrust washer.
(2) If continuity is greater than 0.500 inch, then the pinion clearance
is adjusted to its minimum limit of 0.020 inch and the block test is performed
again to make sure an open circuit exists.
OS 010, 6-P24