Remy 50MT Lever Housing - Manual

Instruction Sheet
10533722
17OC12 DS06035 REV0
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
50MT™ LEVER HOUSING AND LEVER HOUSING SERVICE KIT REPLACEMENT INSTRUCTIONS
NOTE: It is beneficial and possibly necessary to obtain the LH housing service kit. 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 THE LEVER HOUSING 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. Mark the drive and lever housings positions for reassembly.
3. Remove the access plug and gasket from front of lever housing, ensuring gasket is removed.
4. Carefully remove the conventional solenoid plunger adjusting nut so it does not drop into the motor and dispose of it.
5. Remove the six (6) drive housing mounting bolts and the drive housing.
6. Remove the seven (7) lever housing mounting bolts.
7. Remove the lever housing and drive assembly as a unit, keeping armature on its position in the CE housing-frame and field
assembly.
8. If replacing complete Lever housing, go to step 10 of reassembly procedure
9. Remove all the components from Lever housing.
REASSEMBLY PROCEDURES FOR REPLACING THE LEVER HOUSING
1. Soak new wick in 20 weight oil for several hours to allow the 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. Strike it with a hammer until the cup
top is flush with the casting.
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.
4. Install the brake washer by cleaning attaching surface and removing adhesive from brake washer. It can be stuck on the lever
housing or drive assembly.
5. Position shift lever into the housing, and insert the shift lever shaft into housing, passing through holes in shift lever.
6. Push the lever pin into the housing until it is fully seated and install the retainer ring.
7. Remove the seal-oil by carefully prying up and twisting on seal with a large screwdriver or pry bar, making sure not to scratch
the inside diameter of the lever housing hole. This is the sealing surface for the outside diameter of the seal.
8. Install the new seal-oil, using a socket or similar device a little larger than outside diameter of the seal and press into place
with an arbor press. Ensure the seal shell is pressed down evenly, not skewed, and flush with the casting.
For SSL solenoids, remove plunger nut by carefully following these steps. 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.
d. Seat the plunger by simultaneously pushing on plunger nut. Note: 24 volts can be obtained by connecting two 12V
batteries in series.
e. Carefully remove the plunger nut so it does not drop into the motor.
f.
Remove power immediately after nut is removed.