Direct Drive Starter — Disassembly, Checking and Assembly (Mitsubishi Carisma)

Contents: Disassembly ⤓ Cleaning the starter ⤓ Checking the collector ⤓ Checking for a break in the stator…⤓ Checking for a short circuit of the…⤓ Checking the brush holder ⤓ Checking the freewheel clutch ⤓ Checking the bushings of the front…⤓ Replacing the brush and spring ⤓ Checking the short circuit of the…⤓ Checking the short circuit of the…⤓ Checking for a break in the armature…⤓ Assembly ⤓

Disassembly

To disassemble, perform the following operations in sequence.

Fig. 9.16. Direct drive starter: 1 – screw; 2 – front cover; 3 – washer; 4 – limiting ring; 5 – drive lever; 6 – plate; 7 – gasket; 8 – traction relay; 9 – starter anchor; 10 – screw; 11 – tie bolt; 12 – freewheel clutch; 13 – retaining ring; 14 – pole assembly with stator winding; 15 – brush holder assembly; 16 – rear bearing; 17 – rear cover

1. Unscrew screws 1 (Fig. 9.16) and remove traction relay 8.

2. Remove gasket 7 and plate 6.

3. Unscrew screws 10 and remove the back cover 17.

4. Loosen the tie bolts 11.

5. Remove rear bearing 16.

6. Remove the brush holder assembly 15.

7. Remove the pole assembly with the stator winding 14.

8. Remove the starter anchor 9.

9. Remove drive lever 5.

10. Remove washer 3.

Fig. 9.17. Moving the limiting ring down: 1 – limiting ring; 2 – mandrel; 3 – drive gear; 4 – freewheel clutch

11. Using a suitable socket head, push the limit ring down (Fig. 9.17).

Fig. 9.18. Removing the limiting ring: 1 – freewheel clutch; 2 – drive gear; 3 – retaining ring; 4 – special pliers for removing retaining rings

12. Using special pliers, remove the limiting ring, then the limiting ring and the overrunning clutch (Fig. 9.18).

Cleaning the starter

Do not immerse the parts in cleaning solutions (solvents). Such washing of the pole assembly with the stator winding and/or anchor will damage the insulation of the windings. Wipe these parts only with a cloth.

Do not immerse the overrunning clutch assembly with the drive gear in a cleaning solution (solvent). The overrunning clutch is lubricated with grease at the factory, so the solvent will wash the grease out of the clutch.

The freewheel clutch assembly with the drive gear can be wiped with a brush soaked in a cleaning solution and then wiped dry with a cloth.

Checking the collector

1. Place the starter anchor on two V-shaped supports and measure the radial runout of the collector with an arrow-type indicator, which should be no more than 0.05 mm (the maximum permissible value is 0.1 mm).

2. Measure the outside diameter of the manifold.

The nominal value is 32.0 mm.
The maximum permissible value is 31.0 mm.

Fig. 9.19. Measuring the protrusion of the collector lamellas: 1 – collector lamellas; 2 – insulator

3. Check the protrusion of the collector lamellas above the insulator (Fig. 9.19).

The nominal value is 0.5 mm.
The maximum permissible value is 0.2 mm.

Checking for a break in the stator winding

Fig. 9.20. Checking for a break in the stator winding

If the circuit between the brushes is closed, then the excitation winding is in good condition (Fig. 9.20).

Checking for a short circuit of the stator winding to ground

Fig. 9.21. Checking for a short circuit of the stator winding to ground: 1 – pole assembled with stator winding; 2 – brush

Using an ohmmeter, measure the resistance between the brush and the pole (stator housing) (Fig. 9.21). If the resistance tends to infinity, then there is no short circuit of the stator winding to ground.

Checking the brush holder

Fig. 9.22. Checking the brush holder: 1 – brush holder plate

Using an ohmmeter, measure the resistance between the brush holder plate and the brush holder, as shown in Fig. 9.22. If the resistance approaches infinity, the brush holder is in good condition.

Checking the freewheel clutch

1. Hold the freewheel clutch housing with your hand and rotate the drive pinion. The pinion should rotate smoothly, without jamming, in one direction and not rotate in the opposite direction. If the pinion jams or rotates in both directions, replace the freewheel clutch assembly.

2. Check the drive pinion for excessive wear or scoring. If any are found, replace the overrunning clutch assembly. If the drive pinion is damaged, also check the flywheel/torque converter (AT) ring gear for scoring or excessive wear.

Checking the bushings of the front and rear covers

Check the bushings for wear and tear. If any are found, replace the front or rear starter cover assembly.

Replacing the brush and spring

Fig. 9.23. Location of the starter brush wear limit line (1)

Brushes that are worn below the limit line or are oily should be replaced (Fig. 9.23).

1. To replace the brushes, carefully crumble the old brushes with pliers so as not to damage the brush wires.

2. Sand the end of the brush wire to ensure a strong soldering joint.

3. Insert the conductor into the hole of the new brush and solder it. Make sure that the end of the conductor and excess solder do not protrude beyond the surface of the brush.

4. When replacing the negative brush, pull the brush out of the brush holder by pulling the retaining spring.

Checking the short circuit of the armature winding

1. Install the anchor in the growler (a device for checking the winding of the starter and generator).

2. While slowly rotating the anchor in the growler, hold a thin steel plate parallel to and slightly above the anchor. If the anchor winding is faulty (short-circuited), the plate will vibrate and be attracted to the core. Replace the faulty anchor.

Checking the short circuit of the armature winding to ground

Fig. 9.24. Checking the short circuit of the armature winding to ground

Using an ohmmeter, measure the resistance between each commutator plate and the armature core (Fig. 9.24). If the resistance approaches infinity, the insulation is in good condition.

Checking for a break in the armature winding

Using an ohmmeter, measure the resistance between the collector lamellas.

If the resistance is low (the circuit is closed), then the armature winding is in good condition.