Subaru Legacy (2005 year). Manual - part 99

SC(H4SO 2.0)-7

STARTING/CHARGING SYSTEMS

Starter

C: DISASSEMBLY

1. STARTER ASSEMBLY

1) Loosen the nut which holds terminal M of switch
assembly, and then disconnect the connector.

2) Remove the bolts which hold switch assembly,
and then remove the switch assembly, plunger and
plunger spring from starter as a unit.

3) Remove the nuts of both sides, and then remove
rear cover set.

4) Remove the through-bolts and brush holder
screws of both sides, and then detach the rear cov-
er and brush holder assembly.

5) Remove the armature and yoke assembly from
front bracket.

6) Remove the packing A, planetary gear and
packing B.

(A) Terminal M

(A) Switch ASSY

(A) Rear cover set

SC-02094

(A)

SC-00060

(A)

SC-02095

(A)

(A) Brush holder ASSY

(B) Rear cover

(A) Armature

(B) Yoke ASSY

(C) Front bracket

(A) Packing A

(B) Planetary gear

(C) Packing B

SC-00062

(A)

(B)

(A)

(B)

(C)

SC-00063

SC-00064

(A)

(C)

(B)

SC(H4SO 2.0)-8

STARTING/CHARGING SYSTEMS

Starter

7) Remove the plate.

8) Remove the shaft assembly and overrunning
clutch from front bracket as a unit.

NOTE:
Check the following points before removal.
• Lever direction
• Position of internal gear assembly

9) Remove the overrunning clutch from shaft as-
sembly as follows:

(1) Remove the stopper from ring by lightly tap-
ping the stopper with an appropriate tool (such
as a fit socket wrench).

(2) Remove the ring, stopper and clutch from
shaft.

D: ASSEMBLY

NOTE:
Apply grease to the following parts at assembly.
• Sleeve bearing
• Pinion shaft rotating part
• Shaft spline portion
• Inside of reduction system
• Lever fulcrum/Clutch rotating part
1) Install the overrunning clutch to shaft assembly.
2) Install the stopper to shaft assembly as follows.

(A) Plate

(A) Lever

(B) Shaft ASSY

(C) Overrunning clutch

(D) Internal gear ASSY

SC-00065

(A)

SC-00066

(A)

(D)

(C)

(B)

(A) Socket wrench

(B) Ring

(C) Shaft

(D) Stopper

SC-00014

(A)

(B)

(C)

(D)

SC(H4SO 2.0)-9

STARTING/CHARGING SYSTEMS

Starter

(1) Insert the ring into the shaft groove by lightly
tapping it with an appropriate tool (such as a fit
socket wrench).

(2) Install the stopper to ring using a press.

3) Install the shaft assembly to front bracket while
taking care of the following points.

(1) Lever direction

(2) Internal gear position

4) Install the plate.

5) Install the planetary gear.
6) Install the packing A and B while taking care of
installing positions.

7) Install the armature to yoke assembly.

(A) Ring

(B) Stopper

(A) Ring

(B) Stopper

SC-00067

(B)

(A)

SC-00068

(A)

(B)

SC-00069

(A) Plate

(A) Packing A

(B) Packing B

SC-00070

SC-00065

(A)

SC-00071

(A)

(B)

SC(H4SO 2.0)-10

STARTING/CHARGING SYSTEMS

Starter

8) Install the yoke assembly to front bracket in
matching to the groove.

9) Install the brush holder to yoke assembly as fol-
lows.

(1) Press the brush down into brush holder, and
then fix the brush in that position using an appro-
priate tool (such as a fit socket wrench).

(2) Match the brush holder to groove of yoke
assembly, and then slide the brush holder into
yoke assembly to install.

10) Install the rear cover matching it’s groove to
brush holder assembly.

11) Install rear cover set.

12) Install the switch assembly to front bracket as
follows.

(1) Insert the plunger and plunger spring into
switch assembly.
(2) Hook the plunger protrusion on lever edge
to install plunger to front bracket.

SC-00072

SC-00073

SC-00074

(A) Brush holder ASSY

(B) Rear cover

(A) Rear cover set

(A) Switch ASSY

SC-00062

(A)

(B)

SC-02095

(A)

SC-00060

(A)