MAGNETIC SWITCH (SOLENOID) REPLACEMENT

1. Remove the starter according to the procedure in this Section.
2. Clamp the starter motor in a soft-jawed vise.
3. Remove the nut and disconnect the lead from the solenoid M-terminal.
4. Remove the solenoid retaining screws and remove the solenoid. If there are shims between the solenoid and the starter, save them as they are used to adjust the pinion depth clearance.

   Fig. 1: Exploded view of a typical starter assembly showing magnetic switch mounting details

5. Install the replacement solenoid and tighten the retaining screws. Be sure to replace any shims that were removed during disassembly.
6. Proceed as follows:
   1. Leave the lead disconnected from the solenoid M-terminal.
   2. Connect the positive lead from a 12 volt battery to the S terminal of the solenoid and the negative lead to the starter motor body. When the battery is connected, the solenoid should engage and kick out the pinion.

      NOTE: Do not engage the solenoid for more than 20 seconds at a time. If this test must be repeated, wait at least 3 minutes between attempts to allow the solenoid to cool.

   3. With the pinion extended, measure the clearance between the pinion and collar. The clearance should be 0.02–0.08 in. (0.5–2.0mm).
   4. If the gap measurement falls outside the specified range, add or remove shims between the solenoid and drive end housing until the pinion gap is within specification.
   5. Install the lead to the solenoid M-terminal and tighten the nut to 87–104 inch lbs. (10–12 Nm).
7. Install the starter according to the procedure in this section.