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 MANUALSFORD1987ECONOLINE E250, VAN WINDOW EXTENDED, 4.9 YREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALSTARTERSTARTER - MOTORCRAFTOVERHAULREASSEMBLY
1987 Ford Econoline E250, Van Window Extended, 4.9 Y
Starter - MOTORCRAFT: Overhaul: Reassembly
1987 Ford Econoline E250, Van Window Extended, 4.9 YSECTION Reassembly
- Position 3 coils and pole pieces and install attaching screws. As pole shoe screws are tightened, strike frame with a soft hammer to seat and align pole shoes, then stake screws.
- Install remaining coil and retainer. Bend tabs to secure coil to frame. Position new field brush lead on field coil terminal. Install clip to hold brush lead to terminal. Solder lead, clip and terminal together with a 300-watt soldering iron and rosin core solder.
- Ground coil around retaining sleeve by positioning small diameter wire leading from coil under copper tab which attaches contact to frame. Install ground brushes to frame with screws.
- Lubricate armature shaft splines with Lubriplate. Install drive gear assembly on armature shaft. Install new retaining stop ring and stop retainer.
- Install armature in frame. Partially fill drive end housing bearing bore with grease. Position drive gear plunger lever to frame and starter drive assembly and install pivot pin.
- Install plunger lever return spring and drive end housing to frame. Install brush holder, brushes and springs. Install brush holder insulator.
- Position end plate to frame and align plate locator with frame slot. Install and tighten through bolts to 55-75 INCH lbs. (6-8 N.m). DO NOT pinch brush leads when installing end plate. Position drive gear plunger lever cover on starter and tighten cover screw.
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.