Mitsubishi Montero (1991+). Manual - part 188

CAUTION:  Perform tests in less than 10 seconds to prevent coil

          damage.

         1) Disconnect field coil wire from terminal "M" at starter

solenoid. See Fig. 2. Connect jumper wire between positive battery

terminal of 12-volt battery and terminal "S" of starter solenoid.

         2) Connect a second jumper wire from negative battery

terminal and touch starter case. If solenoid plunger is pulled-in,

hold-in coil is good. If not, replace solenoid.

         RETURN TEST

CAUTION:  Perform tests in less than 10 seconds to prevent coil

          damage.

         1) Disconnect field coil wire from terminal "M" at starter

solenoid. See Fig. 2. Connect jumper wire between positive battery

terminal of 12-volt battery and terminal "M" of starter solenoid.

         2) Connect a second jumper wire from negative battery

terminal and touch starter case. Pull pinion outward and release it.

Replace solenoid if pinion remains outward.

         PINION GAP CHECK

         1) Disconnect field coil wire from terminal "M" at starter

solenoid. See Fig. 2. Connect jumper wire between positive battery

terminal of 12-volt battery and terminal "S" of starter solenoid.

         2) Connect a second jumper wire from negative battery

terminal and touch terminal "M" of starter solenoid. See  Fig. 2.

Measure clearance between pinion and stopper. See  Fig. 3.

         3) Clearance should be within specification. See STARTER

SPECIFICATIONS table. Adjust clearance by adding or removing gaskets

between solenoid and front housing.

Fig. 3:  Measuring Pinion Gap

Courtesy of Mitsubishi Motor Sales of America.

         REMOVAL & INSTALLATION

         Remove negative battery cable. If necessary, raise vehicle on

hoist. Remove starter mounting bolts and starter. To install, reverse

removal procedure.

NOTE:    On Raider models with A/T, it may be necessary to disconnect

         transmission oil cooler line for starter removal.

         OVERHAUL

         Check commutator for out-of-round and proper amount of

undercut. Replace or repair armature if not within specification. See

STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear

line (outer line closest to commutator contact surface). Check pinion

gap. See PINION GAP CHECK in this article.

         DISASSEMBLY

NOTE:    Procedures may vary slightly between conventional and

         reduction gear starters.

         1) Loosen nut securing connecting plate-to-magnetic switch

"M" terminal. Remove screws securing magnetic switch and remove switch

(solenoid) assembly. Remove through bolts and brush cover assembly.

Tap yoke assembly loose with wooden mallet. Remove yoke, armature

assembly and pinion shift lever.

         2) Remove pinion stop ring from end of armature shaft by

pushing stop ring to clutch side. Remove snap ring and overrunning

clutch assembly from armature shaft.

Fig. 4:  Disassembled View of Typical Mitsubishi Starter

         CLEANING & INSPECTION

         Clean all parts. Do not use grease dissolving solvent on

overrunning clutch, armature assembly, solenoid assembly or field

coils due to possible damage. Inspect all parts for damage or wear and

replace as required.

         BENCH TESTS

         Brushes & Springs

         Check brush spring tension using a spring scale. Check brush

contact surface condition and brush length. Check lead clip and wire

connections and condition of brush holders. Replace as required. See

Brush Spring Tension and Minimum Brush Length Charts.

         BRUSH & SPRING SPECIFICATIONS

BRUSH SPRING TENSION

Application                                    Ozs. (g)

Chrysler Corp. Imports  ............  46-59 (1302-1670)

MINIMUM BRUSH LENGTH (1)

Application                                    In. (mm)

Chrysler Corp. Imports  ...................  .45 (11.5)

(1) - Minimum brush length should coincide with the

      brush wear mark.

         Armature

         Check external condition of armature for scoring or other

damage. Measure shaft distortion with dial indicator. Replace armature

if shaft distortion exceeds .004" (.10 mm).

         Commutator

         1) Inspect commutator for roughness, grooves, burns or

pitting. Sand lightly with 500 grit sandpaper if necessary. Check

commutator for out-of-round and mica insulators undercut to a depth of

.020-.031" (.5-.8 mm).

         2) If necessary, commutator may be turned less than .04" (1

mm) from original size and mica undercut. Replace if excessively worn.

         Field Coil

         1) Check field coil continuity by connecting test probe of

circuit tester or an ohmmeter to the field coil positive terminal and

brush holder. If circuit is open, replace field coil.

         2) Check for grounding of field coils by placing one probe of

circuit tester on starter housing and other probe to field coil

positive terminal. If little or no resistance, field coil is grounded

and must be replaced.

         Overrunning Clutch Assembly

         1) Inspect pinion assembly and sleeve. Sleeve should slide

freely on armature shaft and spline. If damage or resistance is noted,

replace assembly.

         2) Check pinion and flywheel teeth for excessive rubbing or

damaged teeth. Replace as required.

         Pinion Gear Clearance

         The clearance between the pinion gear and pinion stopper

collar should be .02-.08" (.51-2.03 mm) on Mitsubishi starters, when

solenoid is engaged. Adjust as necessary by changing shims between

solenoid and starter yoke.

Fig. 5:  Measuring Pinion Gear-to-Pinion Stopper Clearance

         Pinion Case Bearing

         Inspect bearing for wear and check side play. If clearance

exceeds .008" (.2 mm), replace bearing. New bearing clearance should

be .002-.004" (.05-.10 mm) for Mitsubishi starters.

NOTE:    Ensure that bearing is installed so that end of bearing is

         flush with gear case end.

         REASSEMBLY

         To reassemble, reverse disassembly procedure. Fill gear case

on reduction gear models with grease. Lightly oil pinion and all

bearing surfaces.