Isuzu Trooper (1998-2002 year). Manual - part 267

6D3–7

STARTING AND CHARGING SYSTEM

Disassembly

1. Loosen the nut(1) on terminal “M” of magnetic switch

and disconnect the connector cable.

2. Remove bolt (2 pcs) (2).

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3. Remove magnetic switch(5).
4. Remove dust cover(4).
5. Remove torsion spring bolts, then the magnetic

switch assembly.

6. Remove torsion spring(3) from magnetic switch

assembly(5).

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7. Remove screw (2 pcs) (8).
8. Remove through bolt (2 pcs) (7).

9. Remove screws and through bolts, then the rear

cover(9) then remove thrust washer(10).

10. Remove brush holder(6).

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11. Raise a brush spring to detach brushes (4 pcs) from

the commutator face and pull off the brush holder(12)
and brush(11).

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12. Remove yoke assembly(14).
13. Remove armature(15).
14. Pull off the yoke assembly, then remove armature,

washer and center bracket.(A) (13).

6D3–8

STARTING AND CHARGING SYSTEM

NOTE: In disassembling the yoke assembly, hold the
armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.

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15. Remove dust cover(17).
16. Remove a dust cover and shift lever(16) from the gear

case.

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17. Remove ball bearing(19).
18. Remove bearing cover(20).
19. Remove a ball bearing and bearing cover from the

gear case(18).

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20. Internal gear(21).
21. Remove internal gear and planet gear(3) (22).

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6D3–9

STARTING AND CHARGING SYSTEM

22. Remove an E–ring(23) from the pinion shaft using a

flat blade screwdriver.

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23. Holding the pinion shaft, push pinion toward the

center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.

24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft.

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Inspection and Repair

Repair or replace necessary parts if extreme wear or
damage is found during inspection.

Armature

Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.

Standard: 33.0 mm (1.30 in)
Limit: 32.0 mm (1.26 in)

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Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).

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6D3–10 STARTING AND CHARGING SYSTEM

Check for continuity between commutator and shaft.
Also, check for continuity between commutator and
armature core,armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).

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Measure runout of armature core and commutator with a
dial gauge.  Repair or replace, if it exceeds the limit.

Armature
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
Commutator
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)

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Polish the commutator surface with sandpaper #500 to
#600 if it is rough.

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Measure the depth of insulator in commutator.  Repair, if it
is below the limit.

Standard: 0.05 mm to 0.8 mm (0.02 in to 0.03 in)
Limit: 0.2 mm (0.008 in)

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Legend

(1) Steel Saw
(2) Insulator
(3) Commutator Segments