Remy 42MT Brush - Manual

Instruction Sheet
10532020
04OC13 REV 4
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™ BRUSH SERVICE PACKAGE OR BRUSH PLATE REPLACEMENT INSTRUCTIONS
NOTE: It is beneficial and possibly necessary to obtain the commutator end (CE) service package,
for reassembly of the brushes. 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 BRUSH PACKAGE AND/OR BRUSH PLATE
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. Remove clip from over crank protection (OCP) connector, if applicable.
3. 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.
4. Remove the four (4) CE screws and CE housing. If replacing the brush plate, proceed to step 6.
5. If only replacing the brushes, remove the four (4) brush springs, four (4) brush screws and four (4) brushes. This also releases the
ground terminal and lead assembly. Proceed to reassembly step 1.
6. Remove the bush-plate with the four (4) brushes and the four (4) Brush springs. Proceed to reassembly step 2.
REASSEMBLY PROCEDURES FOR BRUSH PACKAGE
1. Install the four (4) brush springs, ensuring they are in the same position as removed. This can be
accomplished with needle nose pliers or special tools. Install the brush springs using the tool and hit smoothly
on it, once the spring is directed on track, hit or press on the spring face until it is completely seated.
-
This tool, made from a screwdriver with the same outside diameter as the brush springs first inside
diameters turn.
- The cut off end has an offset slot with the slot depth being about half or 2/3rds the width of the spring. The
offset slot fits inside the first turn of the spring.
2. Install the brush plate assembly into the frame assembly, using the pins to align and install one brush at a
time, pulling the spring to allow them to get into the holder, assuring the same position as removed.
3. 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).
4. Attach the positive brush and field leads to the brush plate with two (2) of the brush screws. Torque screws to
2.3-4.5 Nm (20-40 lb in).
5. Install the square fiber insulator onto the ground stud.
6. Apply bearing type grease onto CE housing’s inner diameter where the frame o’ring is seated and apply a small amount of
SAE20 oil into the bushing area.
7. Install CE housing over the locator pins and CE screws, ensuring the square fiber washer is properly aligned with the anti-turn
feature on the CE housing
8. On models with OCP, assure the OCP connector is seated properly into the housing and torque the CE screws to 4.5-6.8 Nm
(40-60 lb in).
9. 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.
10. Install the large round fiber washer and the remaining parts in the same order as were removed. Torque the large nut on the
ground stud to 27.0-33.8 Nm (20-25 lb ft).