Remy 42MT Drive - Manual

Instruction Sheet
10511628
09SE13 C/P30500 REV3
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™ DRIVE ASSEMBLY 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 te chnical
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 DRIVE 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 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.
5. Remove the six (6) drive housing mounting bolts and the drive housing.
6. Remove the five (5) lever housing mounting bolts.
7. Remove the lever housing, solenoid and drive assembly as a unit. For 37MT motors, it is necessary to remove the pinion stop
and retaining ring from the armature shaft in order to release the drive assembly from the armature. NOTE! The
armature’s retaining ring must be replaced with a new one in order to avoid a potential premature motor failure.
8. Remove the drive assembly from the lever housing.
9. If replacing the brake washer, it is contained in universal service package. Dependent on usage, replacing the brake washer is
recommended. It can be stuck on either the drive or lever housing to assemble.
REASSEMBLY PROCEDURES FOR REPLACING THE DRIVE ASSEMBLY
1. Install the lever housing, solenoid and drive assemblies, noting alignment marks. Insert shift lever yoke into the drive assembly
collar during installation. Install the five (5) mounting screws and torque to 16.3-22.0 Nm (12-16 lb ft). For 37MT motors, install a
new retaining ring into the armature shaft groove and replace the pinion stop.
2. Apply a small amount of SAE20 oil into the drive housing bushing and install the drive housing assembly, aligning the marks. Install
and torque the six (6) mounting bolts to 17.63-29.8 Nm (13-22 lb ft).
3. Replace ground lead to solenoid ground terminal and torque nut to 1.8-4.3 Nm (16-38 lb in).
4.
DANGER!!! Do not reconnect solenoid motor connector strap to field terminal before adjusting the pinion
clearance.
After repair and reassembly, it is necessary before installation on the engine to check and adjust pinion clearance. (See
graphics, page 2).
NOTICE! It is recommended that the SSL instruction sheet, be obtained from our website, www.delcoremy.com, before reinstalling the
plunger nut and adjusting pinion clearance. These instructions are more detailed.
Following these steps carefully is important for adjusting pinion clearance.
Proper care must be exercised when completing these steps to avoid personal injury and/or property damage. Also, to avoid
overheating and possible damage to the solenoid, power should not be applied in excess of one minute.
 DANGER!!! Ensure the stamped metal connector strap is disconnected from the field terminal to prevent the possibility of
motor from rotating.
 Energize solenoid to prevent plunger from rotating and damaging the rubber boot while turning plunger nut to adjust pinion clearance.
 Apply appropriate power (12V or 24V) to solenoid between the switch "S" (+) and “G” ground (-) terminals.
 Seat the plunger by simultaneously pushing on 1/2" plunger nut. Note: 24 volts can be obtained by connecting two 12V batteries in
series.
 Adjust plunger nut to obtain the pinion clearance defined based on the motor series being worked on. (See graphics on page 2)
 Remove power immediately after adjustment is completed