Subaru Legacy III (2000-2003 year). Manual - part 296

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STARTING/CHARGING SYSTEMS

STARTER

6) Remove shaft assembly and overrunning clutch
as a unit.

NOTE:
Before removal, confirm the following:
• Lever direction
• Internal gear assembly position

7) Remove overrunning clutch from shaft assembly
as follows:

(1) Remove stopper from ring by lightly tapping
the stopper with an appropriate tool (such as a
socket).

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

2. BRUSH HOLDER

Slightly open the metal fitting holding the insulating
plate to the brush holder. Remove the insulating
plate.

NOTE:
The brush and spring can be easily removed from
the brush holder at this time.

(A) Lever

(B) Shaft ASSY

(C) Overrunning clutch

(D) Internal gear ASSY

SC-00153

( A )

( B )

( C )

( D )

(A) Socket wrench

(B) Ring

(C) Shaft

(D) Stopper

(A) Brush holder

(B) Insulating plate

(C) Metal fitting

SC-00014

( A )

( B )

( C )

( D )

SC-00154

( A )

( B )

( C )

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STARTING/CHARGING SYSTEMS

STARTER

D: ASSEMBLY

Assemble in the reverse order of disassembly. Do
the following:

NOTE:
When assembling, apply grease to the following
parts.
• Front and rear bracket sleeve bearing
• Armature shaft gear
• Outer periphery of plunger
• Mating surface of plunger and lever
• Gear shaft splines
• Mating surface of lever and clutch
• Ball at the armature shaft end
• Internal and planetary gears
1) Install overrunning clutch to shaft assembly.
2) Install stopper to shaft assembly in the following
order.

(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) When installing shaft assembly to front bracket,
be careful of the following.
• Lever direction

• Internal gear position

• Packing position

4) When installing yoke to the front bracket, match
bolt hole.

(A) Ring

(B) Stopper

SC-00067

(B)

(A)

SC-00068

(A)

(B)

(A) Bolt hole

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SC-00156

SC-00157

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( A )

( A )

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STARTING/CHARGING SYSTEMS

STARTER

5) Install brush holder in alignment with Yoke’s
groove.

6) Install rear bracket.
7) When installing switch assembly, catch plunger
protrusion to lever edge.
8) Install connector to switch assembly terminal M.
9) After assembling parts correctly, make sure
starter operates properly.

E: INSPECTION

1. ARMATURE

1) Check commutator for any sign of burns of rough
surfaces or stepped wear. If wear is of a minor na-
ture, correct it by using sand paper.
2) Run-out test
Check the commutator run-out and replace if it ex-
ceeds the limit.

Commutator run-out:

Standard

0.05 mm (0.0020 in)

Service limit

Less than 0.10 mm (0.0039 in)

3) Depth of segment mold
Check the depth of segment mold.

Depth of segment mold:

0.5 mm (0.020 in)

4) Armature short-circuit test
Check the armature for short-circuit by placing it on
growler tester. Hold a iron sheet against the arma-
ture core while slowly rotating armature. A short-
circuited armature will cause the iron sheet to vi-
brate and to be attracted to core. If the iron sheet is
attracted or vibrates, the armature, which is short-
circuited, must be replaced or repaired.

(A) Dial gauge

(B) V-block

SC-00159

SC-00021

( A )

( B )

(A) Depth of mold

(B) Segment

(C) Mold

(A) Iron sheet

(B) Grower tester

( C )

( B )

( A )

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SC-00023

( A )

( B )

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STARTING/CHARGING SYSTEMS

STARTER

5) Armature ground test
Using a circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is continuity, the ar-
mature is grounded.
Replace the armature if it is grounded.

2. YOKE

Make sure pole is set in position.

3. OVERRUNNING CLUTCH

Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.

CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.

4. BRUSH AND BRUSH HOLDER

1) Brush length
Measure the brush length and replace if it exceeds
the service limit.
Replace if abnormal wear or cracks are noticed.

Brush length:

Standard

12.3 mm (0.484 in)

Service limit

7.0 mm (0.276 in)

2) Brush movement
Be sure brush moves smoothly inside brush holder.
3) Brush spring force
Measure brush spring force with a spring scale. If it
is less than the service limit, replace brush holder.

Brush spring force:

Standard

21.6 N (2.2 kgf, 4.9 lb) (when new)

Service limit

5.9 N (0.6 kgf, 1.3 lb)

5. SWITCH ASSEMBLY

Be sure there is continuity between terminals S and
M, and between terminal S and ground. Use a cir-
cuit tester (set in “ohm”).
Also check to be sure there is no continuity be-
tween terminal M and B.

Terminal / Specified resistance:

S — M / Less than 1 

Ω

Ω

Ω

Ω

S — Ground / Less than 1 

Ω

Ω

Ω

Ω

M — B / More than 1 M

Ω

Ω

Ω

Ω

(A) Service limit line

(B) Brush

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SC-00102

(A)

(B)

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B

M

S