Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1997CHEVY VAN G2500, VAN CARGO EXTENDED, 6.5 FREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALSTARTERSTARTING SYSTEM (G SERIES)OVERHAULSTARTER & SOLENOIDREASSEMBLY
1997 Chevrolet Chevy Van G2500, Van Cargo Extended, 6.5 F
Starter & Solenoid: Reassembly
1997 Chevrolet Chevy Van G2500, Van Cargo Extended, 6.5 FSECTION Reassembly
- Apply a small amount of lubricant to armature shaft and to starter drive contact points. Use 2 sets of pliers to snap pinion stop collar over retainer ring.
- Lubricate solenoid core with grease. Apply grease evenly around inside edge or solenoid core. Apply thickly to first 1/2 (13 mm) inside edge of core. Plunger movement will distribute grease properly. Soak new drive end bushing in oil, before installation, for at least 30 minutes. To install, reverse removal procedure.
- When installing brushes, note that leads may brake off by excessive handling. When installing new pinion stop and stop rings, support driveshaft and clutch under pinion stop. Apply a small amount of lubricant to armature shaft and to starter drive contact points. Use 2 sets of pliers to snap pinion stop collar over retainer ring. Lubricate solenoid core with grease. Apply grease evenly around inside edge or solenoid core. Apply thickly to first 1/2 (13 mm) inside edge of core. Plunger movement will distribute grease properly. To install, reverse removal procedure.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.