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HOMESERVICE MANUALSFORD1969BRONCO BASE, NOT AVAILABLE, 2.8L ENG VIN F, AUTOMATIC TRANSREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALSTARTERS - MOTORCRAFT (AUTOLITE) POSITIVE ENGAGEMENT STARTEROVERHAULREASSEMBLY
1969 Ford Bronco Base, Not Available, 2.8L Eng VIN F, Automatic Trans

Starters - MOTORCRAFT (AUTOLITE) Positive Engagement Starter: Overhaul: Reassembly

1969 Ford Bronco Base, Not Available, 2.8L Eng VIN F, Automatic TransSECTION Reassembly
  1. Install starter terminal, insulator, washers, and retaining nut.
    NOTE: Position slot in screw perpendicular to frame end surface.

    Position coils and pole pieces (with coil leads in terminal screw slot), install retaining screws. As screws are tightened, strike frame several sharp blows with soft-faced hammer to seat and align pole shoes, then stake screws.

  2. Install solenoid coil and retainer, bend tabs to retain coils on frame. Solder field coils and solenoid wire to starter terminal using rosin core solder. Check for continuity and grounds in assembled coils. Position new insulated brush leads on field coil terminal (use clip provided with brushes to hold brush leads to terminal), solder lead, clip, and terminal with rosin solder.
  3. Position solenoid coil ground terminal on nearest ground screw hole, position both ground brushes and install attaching screws. Position commutator end plate on frame with end plate boss in frame slot. Apply thin coating of lubricant on armature shaft splines, install drive assembly on shaft, then install new stop ring and retainer. Position fiber thrust washer (not used on molded commutator armatures) on commutator end of armature and position armature in starter frame.
  4. Position starter drive gear plunger lever to frame and starter drive assembly, install pivot pin. Partially fill drive end housing bearing bore with grease (approximately 1/4 full). Position drive plunger lever return spring and drive end housing to frame, install and tighten through bolts to 55-75 INCH lbs.
    CAUTION: Do not pinch brush leads between plate and frame. Make sure stop ring retainer is seated properly in drive housing.
  5. Install brushes in brush holders, centering springs on brushes. Position drive gear plunger lever cover on starter and install brush cover band with a gasket. Tighten band retaining screw. Check starter no-load current draw.
    POSITIVE ENGAGEMENT SPECIFICATIONS
    Dia. (Inches) Normal Draw (Amps) Normal Speed (RPM) Max. Load (Amps) No Load (Amps)
    4 150-200 180-250 460 70
    4 1/4 150-180 150-290 670 70
    Fig 1: MOTORCRAFT (AUTOLITE) POSITIVE ENGAGEMENT STARTER ASSEMBLY
    G09323995Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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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.