Subaru Legacy III (2000-2003 year). Manual - part 455

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STARTING/CHARGING SYSTEMS

STARTER

6) 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

7) 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.

2. BRUSH HOLDER

Unlock metal clip fixing insulation plate to brush
holder and remove insulation plate.

(A) Lever

(B) Shaft ASSY

(D) Internal gear ASSY

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( A )

( B )

( C )

( D )

(A) Socket wrench

(B) Ring

(D) Stopper

(A) Brush holder

(B) Insulation plate

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( A )

( B )

( C )

( D )

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

• Internal gear position

• Packing position

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

3) When installing rear bracket, match brush holder
and yoke's groove.

4) When installing switch assembly, catch plunger
protrusion to lever edge.
5) After assembling parts correctly, make sure
starter operates properly.

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SC-00156

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(A) Bolt hole

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( A )

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STARTING/CHARGING SYSTEMS

STARTER

E: INSPECTION

1. ARMATURE

1) Check the commutator for any sign of burns of
rough surfaces or stepped wear. If wear is of a mi-
nor nature, correct it by using sand paper.
2) Run-out test
Check the commutator run-out, and then replace if
it exceeds 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.

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.

(A) Dial gauge

(B) V-block

(A) Depth of mold

(B) Segment

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( A )

( B )

( C )

( B )

( A )

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(A) Iron sheet

(B) Growler tester

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( A )

( B )

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STARTING/CHARGING SYSTEMS

STARTER

4. BRUSH AND BRUSH HOLDER

1) Brush length
Measure the brush length, and then replace if it ex-
ceeds 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 the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the 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 the terminals S
and M, and between terminal S and ground. Use a
circuit 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

S — Ground / Less than 1

Ω

M — B / More than 1 M

Ω

6. SWITCH ASSEMBLY OPERATION

1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.

CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.

(A) Service limit line

(B) Brush

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(A)

(B)

(A) Terminal S

(B) Terminal M

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( A )

( B )

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