TM 5-3805-262-34
3-5. STARTER REPAIR (CONT)
INSPECTION, TESTING, AND REPAIR (SHEET 7 OF 7)
k. Inspect bushing assembly (38), seal (61), and boot (68) for cracks, wear and
deterioration.
l. Inspect bushings (22, 56, and 62) for cracks, pitting, groves, and wear.
m. Inspect all other parts for excessive wear, cracks, distortion, or thread
damage.
REASSEMBLY (SHEET 1 OF 6)
a. Assemble plunger assembly:
(1) Push boot (68) and washer (69) onto plunger (70).
(2)
Install inner seat (67), spring (66), and outer seat (65) on plunger
(70).
(3) Press down on outer seat (65) and install retaining ring (64).
b. Assemble lever housing (63):
(1) Using vise or hydraulic press and sleeve, press new bushing (62) and seal
(61) into lever housing (63).
(2) Install oil wick (60) in lever housing (63). Saturate wick with clean en-
gine oil.
(3) Install new plugs (58 and 59). Dent plug (59) using ball-peen hammer to
secure.
c. Assemble drive housing (57):
(1) Using vise or hydraulic press and sleeve,
press new bushing (56) into
drive housing (57).
(2) Install oil wick (55) in drive housing (57). Saturate wick with clean en-
gine oil.
(3)
Install new plug (54). Dent plug (54) using ball-peen hammer to secure.
d. Apply small amount of air-drying adhesive to brake washer (53) for retention,
then position brake washer (53) against lever housing (63).
e. Install new O-rings (47 and 48) on pivot shaft (46).
f. Position shift lever (52) in lever housing (63).
g. Guide plunger (70) into lever housing (63) through shift lever (52).
h. Install pivot shaft (46) through lever housing (63) and shift lever (52).
i. Install retaining ring (45) on pivot shaft (46).
j.
Install lock nut (51): turn lock nut (51) same number of turns as recorded
during disassembly.
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