Remy 42MT Terminal Lead User Manual
Remy Generators
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
Technical support: USA 800 854 0076, Mexico 01 800 000 7378, Brazil 0800 703 3526, South America 55 11 2106 6510 or visit
delcoremy.com
Instruction Sheet
10532025
15JL13 C/P30500 REV2
37MT
™, 41MT™
& 42MT
™ TERMINAL & LEAD ASSEMBLY REPLACEMENT INSTRUCTIONS
MODELS WITH OCP HAVE THE THERMOSTAT ATTACHED
NOTE: It is beneficial and possibly necessary to obtain the commutator end (CE) service parts package, for
reassembly of the terminal and lead assembly.
It is preferable to use new, undamaged parts.
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 TERMINAL & LEAD ASSEMBLY
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.
Note position of the ground stud or mark the CE housing & frame for reassembly.
3.
Remove clip from over crank protection (OCP) connector
,
if applicable.
4.
From the insulated/ground terminal, carefully noting orientation, remove all parts including the solenoid ground lead. Check the
condition of insulators and sealing features and consider replacing them if they are damaged or excessively worn.
5.
Remove the four (4) CE screws and CE housing. If the armature thrust washer is stuck to the CE housing hub, remove it and place
it on the armature shaft.
6.
Remove the remaining insulators from the ground stud, carefully noting orientation for reassembly. Check the condition of insulators
and sealing features and consider replacing them if they are damaged or excessively worn.
7.
Remove the two (2) negative brush screws and remove the ground terminal and lead assembly. The thermostat will be attached to
the lead assemble on models with OCP.
REASSEMBLY PROCEDURES TERMINAL AND LEAD ASSEMBLY PACKAGE
1.
Install ground terminal and lead assembly. Attach the terminal’s negative leads and negative brush leads to the brush plate with
two (2) screws. Torque the screws to 2.3-4.5 Nm (20-40 lb in).
2.
Install the square fiber insulator and fiber washer onto the ground stud. In some grounded 37MT and 41MT starters it will not be
necessary to install the ground terminal and fasteners.
3.
Apply bearing type grease onto inner diameter on CE housing where the frame o’ring is seated and apply a small amount of SAE20
oil into the bushing area. Install CE housing over the locator pins and CE screws, insuring the square fiber washer is properly aligned
with the anti-turn feature on the CE housing
4.
On models with OCP, insure the OCP connector is seated properly into the CE housing and torque screws to 4.5
–6.8 Nm
(40
–60 lb in).
5.
First insert the small round fiber insulator and then the rubber bushing over the Insulated/ground stud into the hole on the CE
housing. Installing the rubber bushing prior to installing the CE housing can pinch the bushing and destroy its sealing
capabilities.
6.
Install the large round fiber washer and the remaining parts in the same order as were removed. Torque the large nut on
ground stud to 27.0-33.8 Nm (20-25 lb ft).
7.
Install clip on OCP connector.
8.
DANGER!!!
Do not reconnect solenoid motor connector strap to field terminal before adjusting the pinion clearance.
NOTICE! After repair and reassembly it is necessary, before installation on the engine, to check and adjust pinion
clearance. It is recommended the solenoid replacement instruction sheet, be obtained from our website,
.
9.
Reinstall starter and connect cables and other leads, as removed.
10. Reconnect the negative (-) cable at the battery.