ARMY TM 9-2815-255-24
AIR FORCE TO 38G1-95-2
MARINE CORPS TM 2815-24/4
Install five rollers (21), retainer (20), and starter pinion (19) in housing (16).
Place steel ball (18) in overrunning clutch (17) and install both in housing (16).
Position assembled housing (16) on magnetic switch assembly and secure with three screws (15).
Tighten screws 5.1 to 8.7 ft-lbs (6.9 to 11.8 Nm).
Install armature (14) in magnetic switch assembly (24).
Position brush holder (13). Lift springs and install brushes, refer to FIGURE 3-16. Ensure negative brushes
(connected to brush holder) are installed in negative holes (not insulated) and positive brushes (connected to
yoke) are installed in positive holes (separated from plate with insulator).
Ensure positive brush leads are not grounded.
Position cover (12, FIGURE 3-15) on yoke (38) engaging tab on cover with lead wire grommet.
Secure with two screws (11). Tighten screws 1.95 to 3.40 ft-lbs (2.6 to 4.6 Nm).
Position yoke assembly (38) on magnetic switch assembly (24) engaging tab on yoke assembly with notch in
magnetic switch. Secure with two through bolts (7), new lockwashers (8), washers (9), and new preformed
packings (10). Tighten through bolts 5.1 to 8.7 ft-lbs (6.9 to 11.8 Nm).
Connect yoke assembly lead wire (6) to terminal on magnetic switch assembly with washer(s) and nut (4).
Tighten nut to 18.1 to 26.0 ft-lbs (24.5 to 35.3 Nm). Ensure rubber boot (36) is installed securely.
To aid in installing starter and spacer, place a 3/8 inch x 3 inches (9.52 mm x 7.62 cm) guide stud
in one of the starter mounting holes in flywheel housing.
Remove cover in flywheel housing.
Place starter on flywheel housing and secure with two screws (1, FIGURE 3-15), new lockwashers (2), and
washers (3). Tighten screws 30 to 35 ft-lbs (41 to 47 Nm).
Connect electrical leads to starter as tagged during removal.
Install coolant overflow bottle and mounting plate, refer to end item maintenance manual.
Connect negative battery lead to battery.
Change 3 3-42