Genuine Volvo 245 Starter

Volvo 245 Starter Parts and Q&A

• Starter
  5003708
  Q: What are the steps involved in dismantling and inspecting a starter motor on Volvo 245?

  A:

  Remove the small cover at the front end of the shaft then lift away the locking washer and the adjustment washer. Mark the drive bearing and commutator bearing brackets, remove the two through-bolts and undo them, remove the commutator bearing shield after making sure the brushes and retainers are still in place on the armature. The brush retaining plate is removed from the armature, noting the position of the washers, the brushes are pulled from the holders. Take off the brush gear from the armature, care being taken not to lose the shims; when the brush gear is removed, the negative brushes will drop off, the positive brushes remaining attached to the field winding. Unscrew the nut that holds the field terminal connection to the solenoid, undo and remove the screws holding the solenoid to the end of the driveshaft and lift away. Remove the drive end shield and armature from the starter body and remove the pivot pin of the engagement lever, which removes the rubber washer and the metal washer. Raise the armature with pinion and lever from the drive end shield, knock back the stop washer and remove circlip from the armature. And finally remove the stop ring and drive pinion assembly, and clean up the different components with a compressed air jet. Examine the rotor for mechanical damage (e.g. worn or bent shaft, scored or burnt commutator or damaged windings) If the rotor shaft is bent or worn it must be renewed. If the commutator is scored or worn unevenly, it may be skimmed on a lathe, it being taken in small cuts with as little material removed as possible, and the insulation between the laminations being undercut to a depth of 0.016 in (0.4 mm) with a hacksaw blade with the sides of its teeth ground off. Inspect the housing and field winding for damage caused by the rotor and if possible test the field winding to make sure it is not earthed by connecting the contact points of a test light and battery to the housing and field winding and if the light comes on the winding or lead through body is damaged. Remove the through lead and test again, if the light stays on the field coils are earthed and will need to be renewed. Examine the brush holders carefully, renewing any worn or damaged parts, and examining generally the other parts, renewing any that are worn or damaged, using new circlips during reassembly. To remove the brushes, unsolder them from their attachments in the brush holder and field winding and then solder the new brushes in position, taking care not to let solder run down on to the brush leads, which can interfere with necessary movement and reduce brush spring. Ideally, replace the brushes when they have worn out to a length of 0.51 in (13 mm). Reassembly of the starter motor is carried out in reverse order according to the dismantling procedure and lubrication of the starter motor at designated lubrication points.