Remy 42MT SSL Solenoids - Manual (Page 2)

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B. SEMI-SOLID-LINK SOLENOID REMOVAL INSTRUCTIONS
(See illustrations pages 3 & 4)
1. For older 42MT models, loosen 3/4” nut on solenoid motor terminal [1]. For 37MT, 41MT and newer
42MT starters, loosen E8 Torx Head solenoid motor terminal screw [1*].
2. Remove E8 Torx Head screw [2] at field connection on starter frame.
3.
For older 42MT models, remove 3/4” nut from solenoid motor terminal [1]. For 37MT, 41MTand newer
42MT starters, remove E8 Torx Head solenoid motor terminal screw [1*].
4. Remove solenoid to starter field connector strap [3]. Dispose of old design connector strap.
5.
For insulated models (flexible ground cable not shown), remove top 3/8” nut and washer assembly from
ground terminal [5] of solenoid.
6. Remove flexible ground cable (not shown) from the solenoid ground terminal [5].
7. Remove access plug and gasket [4] from front of lever housing, ensuring gasket is removed.
8. Remove 1/2" plunger nut [8] by carefully following the steps outlined below. Proper care must be
exercised when completing this step to avoid personal injury and property damage. Also, to
avoid overheating and possible damage to the solenoid, power should not be applied in excess
of one minute.
a) Solenoid must be energized for removal of 1/2" plunger nut [8] to prevent plunger from rotating and
damaging the rubber boot. DANGER!!! Ensure stamped metal connector strap [3] is
disconnected to prevent motor from rotating.
i. Check required voltage (12V or 24V) stamped on solenoid metal case to energize solenoid.
ii. Apply appropriate power (12V or 24V) to solenoid between switch "S" [12] (positive lead) and
ground [5] (negative lead) terminals. Seat the plunger by simultaneously pushing on 1/2" plunger
nut [8]. Note: 24 volts can be obtained by connecting two 12V batteries in series.
b) Remove 1/2” plunger nut [8] carefully, so it does not drop into motor, and dispose.
c) Remove power immediately after nut is removed.
9. Remove three E8 Torx Head solenoid mounting screws [6].
10. Remove complete solenoid [7] and plunger assembly from lever housing.
C. SEMI-SOLID LINK SOLENOID INSTALLATON INSTRUCTIONS (See illustrations pages 3 & 4)
Using replacement semi-solid link solenoid:
1. Slide solenoid over lever housing register [10].
2. Orient solenoid so that the flat flange on the solenoid metal case aligns with the flat flange on the
housing.
3. Verify that the plunger rod [11] is inside the shift lever guide.
4. Install three E8 Torx Head solenoid mounting screws [6] and torque to 14.1-21.5 Nm (125-190 lb in).
5.
Install a new 1/2” plunger nut [8] by hand finger tight. Use of force can rotate the plunger and
damage the rubber boot.
6. Check and adjust pinion clearance. Proper care must be exercised when completing this step to
avoid personal injury and property damage. Also, to avoid overheating and possible damage to
the solenoid, power should not be applied in excess of one minute.
a) Solenoid must be energized to prevent plunger from rotating and damaging the rubber boot while
tightening plunger nut [8] to adjust pinion clearance. Warning: Ensure stamped metal connector
strap [3] is disconnected to prevent motor from rotating.
i. Check required voltage (12V or 24V) stamped on the solenoid metal case.
ii. Apply appropriate power (12V or 24V) to solenoid between switch "S" [12] (positive lead) and
ground [5] (negative lead) terminals. Seat the plunger by simultaneously pushing on 1/2" plunger
nut [8]. Note: 24 volts can be obtained by connecting two 12V batteries in series.