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Hummer H1 (2002+). Manual - part 201

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Electrical System 12-31

05745159

Figure 12-54: Starter Connections

STARTER OVERHAUL

Disassembly

Remove starter.

Remove plug and gasket from pinion housing (Figure 12-55).

Figure 12-55: Core Shaft Nut Removal

Remove core shaft nut with socket, fabricated socket
holding tool, and hex wrench (Figure 12-55). Holding tool
can be fabricated from suitable size square tube. Or, a
suitable size thin wall, deep socket can be used.

Remove connector nuts and remove solenoid connectors
from frame assembly and solenoid (Figure 12-56).

Figure 12-56: End Plate Removal

Remove solenoid screws and remove solenoid.

Scribe alignment marks on end plate and frame.

Remove end plate bolts and remove end plate and gasket.

Remove thrust washer and spacer from armature shaft.

Remove felt wick from end plate.

10. Scribe alignment marks on pinion housing and frame

(Figure 12-57).

Figure 12-57: Frame Removal

11. Remove screws attaching pinion housing to frame.

12. Remove frame, gasket, and O-ring from pinion housing.

13. Remove two plugs and pin from pinion housing and shift

lever (Figure 12-58).

TO GLOW PLUG

CONTROLLER

SOLENOID

WIRE

STARTER CABLES

(FROM BATTERY)

PINION HOUSING

GASKET

PLUG

LOCKNUT

CORE SHAFT

SOCKET HOLDING

TOOL

HEX WRENCH

SOCKET

SOLENOID

CONNECTOR

FRAME

SOLENOID

MARK

SPACER

FELT

WICK

ARMATURE

SHAFT

GASKET

SOLENOID

CONNECTOR

THRUST

WASHER

END

PLATE

SCRIBE

MARK

SCRIBE

PINION

HOUSING

MARK

O-RING

GASKET

FRAME

SCRIBE

MARK

SCRIBE

4-1-00

12-32

Electrical System

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Figure 12-58: Starter Drive Disassembly

14. Clamp pinion housing in vise and remove screws from end

plate and pinion housing (Figure 12-59).

15. Slide armature, end plate, and shift lever out of pinion

housing.

Figure 12-59: Armature Removal/Installation

16. Remove snap ring and pinion stop from armature shaft,

and slide clutch off armature shaft (Figure 12-58).

17. Remove washer and plate from armature shaft (Figure 12-58).

18. Remove gasket from armature plate.

19. Remove nuts, lockwashers, screws, copper washers, and

negative brush leads from frame. Remove brushes from
brush holders (Figure 12-60).

Figure 12-60: Brush and Holder

Removal/Installation

20. Remove screws and positive brush leads from field coil

brackets. Then remove brushes from holders.

21. Remove springs from brush holders.

22. Remove nut and lockwasher assemblies and rubber

washers from solenoid housing. Discard rubber washers
(Figure 12-61).

Figure 12-61: Solenoid Housing

Disassembly/Reassembly

23. Pull cover away from solenoid housing and remove screw

and washer from lug on cover and series winding lead.

24. Remove cover and gasket from solenoid housing.

25. Holding core shaft, remove locknut, washer, and contact

from core shaft (Figure 12-62).

26. Remove and separate spring from core shaft and washer.

27. Remove snap ring, spring retainer, spring, spring retainer,

rubber boot, and washer from core shaft (Figure 12-62).

PLUG (2)

PIN

PINION

HOUSING

SHIFT LEVER

SNAP RING

PINION STOP

CLUTCH

ARMATURE

GASKET

PLATE

ARMATURE

SHIFT LEVER

PINION

HOUSING

ARMATURE

PLATE

FRAME

FIELD COIL

BRACKET

POSITIVE

BRUSH LEAD

NEGATIVE

BRUSH LEAD

BRUSH

HOLDER

SPRING

COVER

GASKET

SERIES

LUG

SOLENOID

HOUSING

WINDING LEAD

4-1-00

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Electrical System 12-33

05745159

Figure 12-62: Solenoid Components

Inspection

Inspect clutch for broken spring, damaged gear or splines, and
non-lockup. Replace clutch if damaged (Figure 12-63).

Inspect brushes for cracks, roughness, galling, wear, or dam-
aged lead. If one brush length is less than 0.315 in. (8 mm) or
has other damage, replace all brushes as a set.

Inspect springs for breaks, distortion, or other damage. Replace
any damaged springs.

Inspect bearings in head end and pinion housing for cracks,
roughness, galling, or damage. Replace bearings if defective
(Figure 12-63).

Inspect pinion housing for cracks, damaged pinion bearing,
and damaged threads. Repair minor thread damage. Replace
starter if otherwise damaged.

Inspect commutator for damage due to arcing (burned spots
and pitting), damaged shaft, splines, or threads. Replace starter
if commutator is damaged.

Test armature, field coils, and brush holders for shorts,
grounds, and open circuits with an armature tester. Replace
starter if any one of these parts is defective.

Inspect core spring, core shaft, and rubber boot for damage.
Replace parts if damaged (Figure 12-64).

Inspect contact for burns or damage. Replace contact if burned
or damaged.

Inspect housing of frame assembly, head end, and solenoid
housing for cracks or damage. Replace starter if any part is
damaged (Figures 12-64 and 12-65).

Figure 12-63: Starter Components

SOLENOID

HOUSING

SPRING

CONTACT

CORE
SHAFT

SPRING

RETAINER

SPRING

SNAP RING

BOOT

SPRING

RETAINER

END PLATE

BEARING

BRUSH

HOLDER

FIELD

COIL

FRAME ASSEMBLY

SPRING

BRUSH

COMMUTATOR

ARMATURE

SPLINES

CLUTCH

GEAR

PINION HOUSING

BEARING

(IN HOUSING)

4-1-00

12-34

Electrical System

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Figure 12-64: Solenoid Components

Starter Assembly

Assemble washer, rubber boot, spring retainer, spring, and
spring retainer on core shaft and secure with snap ring
(Figure 12-61).

Place core shaft assembly in solenoid housing.

Install washer, spring, contact, washer and locknut on core
shaft.

Place gasket on cover and secure series winding lead to
lug with screw and washer (Figure 12-61).

Install cover and gasket on solenoid housing and secure
with four rubber washers and nut and lockwasher
assemblies.

Install negative brushes and positive brushes in brush
holders and retain with four springs (Figure 12-60).

Connect positive brush leads to field coil brackets with
two screws.

Connect negative brush leads to frame with copper
washers, screws, lockwashers, and nuts.

Cover negative lead screw heads with silicone adhesive
sealant.

10. Apply chassis grease to armature shaft, shift lever studs,

groove of clutch, and inside diameter of end plate
(Figure 12-63).

11. Place washer, end plate, and gasket on armature shaft.

12. Place washer, clutch, and pinion stop on armature shaft

and retain with snap ring. Position armature and shift lever
in position shown for installation (Figure 12-59).

13. Install shift lever on clutch with shift lever studs engaged

in clutch groove.

14. Start shift lever into pinion housing as armature is

positioned in large bore of pinion housing. Then install
screws through armature plate into pinion housing.
Tighten screws to 40 lb-in. (5 N•m) (Figure 12-59).

15. Insert pin through pinion housing and shift lever. Then

install two plugs in pinion housing (Figure 12-58).

16. Install O-ring and gasket in pinion housing (Figure 12-66).

17. Coat end plate-to-frame screws with adhesive sealant.

CAUTION: As armature is inserted into frame assembly, care-
fully align brushes on commutator. Brushes chip and break
easily.

18. Align scribe marks on frame and pinion housing, and

install armature and pinion housing in frame assembly.
Install and tighten screws to 50 lb-in. (6 N•m).

19. Saturate felt wick with engine oil and install in end plate

(Figure 12-65).

Figure 12-65: Starter End Plate Installation

20. Install spacer and thrust washers on armature shaft.

21. Align scribe marks on end plate and frame and install end

plate. Tighten end plate screws to 25 lb-in. (3 N•m).

22. Coat threads of end plate screws with adhesive sealant.

23. Install end plate screws.

24. Check end play as described in following procedure.

25. Coat ribbed area of core shaft boot with lithium grease

(Figure 12-67).

26. Align end of core shaft in hole in shift lever and install

solenoid on frame. Tighten solenoid screws to 50 lb-in. (6
N•m).

27. Install core shaft nut. Tighten nut with socket, fabricated

tool, and hex wrench (Figure 12-55)

CORE

SPRING

RUBBER

BOOT

SOLENOID

HOUSING

CONTACT

SPRING

CORE

SHAFT

FRAME

ASSEMBLY

THRUST

WASHER(S)

FELT

WICK

MARK

GASKET

SPACER

MARK

SCRIBE

END

PLATE

4-1-00

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