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 MANUALSFORD1987CUTAWAY 6.9 1REPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALSTARTERSTARTER - 6.9L DIESELOVERHAULBENCH TESTINGPINION CLEARANCE
1987 Ford Cutaway 6.9 1
Pinion Clearance
1987 Ford Cutaway 6.9 1SECTION Pinion Clearance
- Disconnect motor field coil connector and insulate it carefully. Connect a battery from solenoid switch terminal to solenoid frame. Momentarily flash a jumper lead from motor terminal to solenoid frame.
- This shifts pinion into cranking position. Push pinion back toward commutator end to eliminate slack. Measure distance between pinion and pinion stop. When installing starter, check clearance between pinion and flywheel ring gear teeth.
- Insert a .020" (.60 mm) diameter wire, about 3" (76 mm) long, with a 1/4" to 1/2" 90 degree bend in end between pinion tooth and ring gear. Center pinion tooth between flywheel teeth when making measurement.
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.