Ford Orion. Manual - part 42
18 Starter motor -
brush renewal
3
1 Remove the starter motor from the vehicle
as described in Section 17.
Bosch
2 Undo the two retaining screws and remove
the end cap (see illustrations).
3 Wipe free the grease from the end of the
armature shaft, then prise free and remove the
C-clip from the shaft groove. Depending on
the type fitted, remove the washer/spacer(s)
(see illustration).
4 Unscrew and remove the two through-
bolts, then remove the commutator end
plate/housing from the starter motor (see
illustration).
5 On the Bosch D-type starter motor,
disconnect the brush link lead from its
terminal stud (see illustration).
6 Withdraw the brush plate assembly (taking
care not to damage the terminal brushes),
then release the brushes from their holders in
the brush plate.
7 Clean and inspect the brush assemblies. If
the brushes have worn beyond (or down to)
the specified minimum length, they must be
renewed as a set. In the case of the D-type
motor, the complete brush plate unit will have
to be renewed. To renew the brushes on the
other types, the brush leads must be
unsoldered from the brush plate terminals,
and the new brush leads soldered in their
place.
8 Prior to refitting the brushes, check the
condition of the commutator face on which
they run. Wipe the commutator with a solvent-
moistened cloth. If the commutator is dirty, it
may be cleaned with fine glass paper, then
wiped with the cloth.
9 Fit the new brushes using a reversal of the
removal procedure. To ease fitting of the
brush assembly over the end of the
commutator, press the brushes back into their
holders, and insert a suitable socket or tube to
retain them. Align the socket with the end of
the commutator, and slide the brush
assembly from the socket onto the
commutator and into position as shown (see
illustration). Make sure that the brushes
move freely in their holders.
5•12 Engine electrical systems
18.9 Brush plate unit assembled over a
socket with the same outside diameter as
the commutator to ease assembly
18.5 Detach the brush link lead (Bosch D-
type starter motor)
18.4 Remove the commutator endplate
(Bosch starter motor)
18.2D Remove the starter motor end cap
(Bosch starter motor)
18.3 Remove the C-clip and any washers
(Bosch starter motor)
18.2C Exploded view of the Bosch EV starter motor
1 Yoke
2 Return spring
3 Solenoid armature
4 Rubber block
5 Actuating arm
6 Drive pinion and
clutch
7 End housing
8 C-clip and thrust
collar
9 Circlip
10 Spacers
11 Cover plate
12 Spacer
13 Output shaft and
planet gear unit
14 Ring gear
15 Commutator end
housing cap
16 C-clip
17 Shims
18 End housing
19 Brushes
20 Brush plate
21 Yoke
22 Armature
23 Retaining plate
24 Through-bolt