DIY: How to Rebuild a Starter Motor

Video tutorial on how to rebuild a starter yourself at home. This is a great way to save money considering it’s only about $10 for replacement parts and a rebuilt replacement can around $150 depending on the vehicle. The repair maybe slightly more if you have to replace a solenoid.

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Tools/Supplies Needed:
-new brushes, bushings or bearings, and solenoid
-multimeter
-600 grit aluminum oxide sandpaper
-ratchet and socket set
-paint
-grease
-electrical contact cleaner
-wire brush
-scraper
-clean rags
-degreaser
-pliers
-adjustable wrench
-tape
-paint marker

Procedure:
-remove starter from vehicle
-tape up any exposed holes on the starter
-clean the outside using a scraper and wire brush
-use a paint marker to mark any case seams
-remove the main power cable coming off the solenoid
-remove the outer bolts on the starter case
-these are extremely long and small, so take your time as you can risk breaking them depending on the condition of your starter
-the starter should pop right apart
-do not force the starter apart as there are plastic components which can break
-remove the solenoid
-the plunger will fit into a plastic fork so it does need to be shifted to one side so it can be removed from the unit
-remove rubber cap holding the engagement lever into place, then remove the final drive assembly
-the gear reduction just slides apart and inside you will find a series of gears
-remove the two bolts on the backside and pull off the cap
-remove the small rubber cap on the side that both holds and insulates the cable which just slides out
-pull back on the shaft to help assist the armature and brushes out
-pop the metal clips back and remove the cap on the brush carrier
-fully remove the metal clips and pull the brushes out, be extremely careful not to lose the springs in the process
-using a plastic safe degreasing, clean up any old lubricant on any parts with a clean rag
-disassemble the final drive, there is a c clip at the end of the shaft that holds the pinion gear in place
-remove the pinion gear and clutch assembly, inspect for any damage and replace if necessary
-remove another c clip, this time using needle nose plies to separate the final drive shaft
-clean up everything again with a degreaser
-there will be a bushing inside the case, so inspect that for any damage and replace if necessary
-for reassembly, apply a film of grease to any moving parts
-use a high quality grease throughout the starter motor, something which will maintaining good lubricating qualities in cold climate and not melt under high heat
-the grease will provide lubrication and hold the ball into place, make sure you do not lose it
-there will be a bushing in the end cap housing, therefore make sure it is in good condition with not play, replace if necessary
-I used a hacksaw blade to cut a slit in the bushing, do not cut all the way through as we do not want to mark the casing
-using a chisel, crush the bushing and then you’ll be able to remove it
-clean up any old dirt or lubricant
-gently insert the new bushing with a hammer, once it becomes a little lower, use the old bushing to help assist it into place and ensure it sits into the same location as before
-clean up the armature using electrical contact clean and a tooth brush
-commutator resurface using 600 grit aluminum oxide sandpaper and a drill
-clean up the commutator using electrical contact cleaner and ensure the spaces between the commutator bars are clean
-the mica in these spaces should also be about 1mm lower
-using a multimeter, test the armature
-wash the inside of the start case with contact cleaner to remove any contaminants
-checked the solenoid with a multimeter
-for reassembly, install the final drive back into the case
-apply a light amount of oil to the oilite bushings if desired
-install rubber cap, solenoid and then motor case
-install the new bushes in the carrier and seat using 600 grit aluminum oxide sandpaper so they match the contour of the commutator
-wash everything with electrical contact cleaner
-assembly the starter

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