Remy 42MT Lever Housing - Manual

Instruction Sheet
10532026
15JL13 C/P30500 REV2
NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
©
2012 Remy International, Inc. All rights reserved 1
37MT ™, 41MT™ & 42MT™ LEVER HOUSING ASSEMBLY OR PARTS REPLACEMENT INSTRUCTIONS
WARNING!!! ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE –
INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY STARTING MOTORS.
FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE.
Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical
capabilities should be handled by a professional installation specialist.
FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING
THE STARTER.
DISASSEMBLY PROCEDURES FOR REPLACING THE LEVER HOUSING ASSEMBLY AND SERVICE PARTS
DANGER!!! ALWAYS DISCONNECT BATTERY GROUND BEFORE REMOVING OR REPLACING CABLES AT THE STARTER.
FAILURE TO DISCONNECT THE BATTERY GROUND CABLE CAN LEAD TO SERIOUS INJURY.
1. Remove vehicle leads connected to the starter, noting their positions for reinstallation of starter, and remove starter
2. Mark the nose and lever housings position for reassembly.
3. Remove field coil connector strap and solenoid ground lead from the solenoid.
4. Remove the access plug and gasket from front of lever housing, ensuring gasket is removed.
NOTICE! It is recommended that the SSL solenoid instruction sheet, be obtained from our website, www.delcoremy.com, before
removing and reinstalling the pinion clearance adjustment nut.
5. Remove the three (3) solenoid mounting screws and remove either the SSL or conventional solenoid.
a. Carefully remove the conventional solenoid plunger nut so it does not drop into the motor and remove the plunger assembly.
6. Remove the six (6) drive housing mounting bolts and the drive housing.
7. Remove the five (5) lever housing mounting bolts.
8. Remove the lever housing and drive assembly. For 37MT motors, remove the drive housing and remove the retaining ring from
the armature shaft, in order to release the drive assembly from the armature. NOTE! The armature retaining ring must be
replaced with a new one in order to avoid a premature motor failure.
9. If replacing the lever housing assembly, go to step 11 of reassembly. If reconditioning the lever housing with service parts,
continue to step 10.
10. Remove all parts from the lever housing assembly, carefully noting the two (2) braces on the shift lever face of the pinion.
REASSEMBLY PROCEDURES FOR REPLACING THE LEVER HOUSING ASSEMBLY OR SERVICE PARTS
1. Soak new wick in 20 weight oil for several hours to allow oil to penetrate and install into the housing.
2. Align the cup with the wick hole, open end down, and tap it into place until it is flush with the housing. It is best to use a deep well
socket or similar devise about the same size as the outside diameter of the wick cap.
3. Install the lever housing bushing. This requires using an arbor press or a special tool. The recommended special tool is like a large
pin punch which has about the same outside diameter as the armature shaft for that end with a shoulder on it about the same outside
diameter as the bushing. Press busing, from end with seal, until flush with casting surface.
4. Install the brake washer by cleaning attaching surface and removing adhesive from brake washer. It can be stuck on the lever
housing or pinion.
5. Position shift lever into the housing, with the two (2) braces facing the pinion, and insert the shift lever shaft into housing, passing
through the holes in shift lever.
For SSL solenoids, remove plunger nut by carefully following these steps or preferably instruction sheet, 10512652, from our
website. Proper care must be exercised when completing these steps to avoid personal injury. Also, to avoid overheating
and possible damage to the solenoid, power should not be applied in excess of one minute.
a. DANGER!!! Ensure the stamped metal connector strap is disconnected from the field terminal to prevent the
possibility of motor rotating.
b. Solenoid must be energized for removal of plunger nut to prevent plunger from rotating and damaging the rubber boot.
c.
Apply appropriate power (12V or 24V) to solenoid between the switch "S" (+) and ground “G” (-) terminals. Seat the plunger
by simultaneously pushing on plunger nut. Note: 24 volts can be obtained by connecting two 12V batteries in series.
d. Carefully remove the plunger nut so it does not drop into the motor.
e. Remove power immediately after nut is removed.