5-3. STARTER MAINTENANCE
a. S t a r t e r .
This task covers removal, cleaning, inspection and repair, and in-
stallation of starter and its associated cables and ground wire.
TOOLS: No. 1 Common Organizational Maintenance Tool Kit
Combination box and open end wrench set
Socket wrench set, 3/8 inch drive
Torque wrench, 1/2 inch drive
Torque wrench, 3/8 inch drive, 200 lb-in capacity
Automotive Mechanics Tool Kit
Socket wrench set, 1/2 inch drive
MATERIALS/PARTS: Clean cloths (Appendix C, item 1)
Cleaning solvent P-D-680 (Appendix C, item 2)
Detergent (Appendix C, item 3)
Insulation tape (Appendix C, item 5)
Isopropyl alcohol (Appendix C, item 15)
Electrical cleaner (Appendix C, item 19)
Electrical sealer (Appendix C, item 20)
PRELIMINARY PROCEDURE: Left front side panel removed (page 9-14) and
battery ground cable disconnected (page 5-148).
REMOVAL (SHEET 1 OF 2)
Loosen and remove nut (1) and lock washer (2) and disconnect cable (3)
from terminal S of solenoid.
Loosen and remove nut (4) and lock washer (5) and d
7, and 8) from solenoid BAT terminal.
(3) Remove nut (9) and lock washer (10) and disconnect
(12) from starter ground terminal.
( 4 ) I f n e c e s s a r y t o r e p l a c e c a b l e ( 3 o r 6 ) , r e m o v e c a bl
(a) Remove engine left rear side panel (page 9-14).
isconnect cables (6,
cable (11) and wire
e as follows:
( b ) A t r e l a y a n d c i r c u i t b r e a k e r b r a c k e t,
l o c a t e s t a r t e r r e l a y ( t h e 4 - t e r m i-
nal relay). At two large terminals, remove two nuts (20) and disconnect
cables (3 and 6) from starter relay terminals.
(c) At battery and solenoid cables near starter, cut and remove three tie
s t r a p s ( 1 9 ). Remove cables (3 and 6) from loader and discard tie straps.
(5) If necessary to replace starter ground wire (12), remove wire as follows:
(a) At engine oil cooler, remove capscrew (21) and lock washer (22) and dis-
connect wire (12).
(b) At battery and solenoid cables near starter, cut and remove three tie
straps (23). Remove wire (12) from loader and discard tie straps.