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 MANUALSPONTIAC19876000 SAFARI LE, 2.5 RREPAIR AND DIAGNOSISENGINE MECHANICALSTARTERSTARTER - DELCO-REMYBENCH TESTSREASSEMBLYALL MODELS
1987 Pontiac 6000 Safari LE, 2.5 R
All Models
1987 Pontiac 6000 Safari LE, 2.5 RSECTION All Models
- Lubricate the drive end of the armature shaft with silicone lubricant. Install the center bearing (27MT only) with the bearing facing the armature winding. Install the fiber washer on the armature shaft.
- Slide the clutch assembly onto the armature shaft with the pinion away from the armature. Slide the retainer onto the shaft with the cupped side facing the shaft end. Install the snap ring into the groove on the shaft. Install the thrust washer.
- Position the retainer and the thrust washer with the snap ring located between them. Using 2 pliers, grip the retainer and thrust washer; then squeeze it until the snap ring is forced into the retainer and is held securely in the armature shaft groove.
- Lubricate the drive gear housing bushing. Engage the shift lever yoke with the clutch and slide the complete assembly into the drive gear housing.
- Install the center bearing screws and the shift lever pivot bolt. Install drive housing, tighten though bolts and install the solenoid assembly on the drive gear housing. Test starter and install.
- Apply sealer to the solenoid flange where the field frame contacts it. Position the field frame against the drive gear housing on the alignment pin, being careful not to damage the brushes. Lubricate the commutator end frame bushing with lubricant.
- Install the washer on the armature shaft and slide the end frame onto the shaft. Install the through bolts and tighten. Connect the field coil connector to the solenoid "M" terminal. Ensure the through bolts pass through the bolt holes in the insulator. Check the pinion clearance.
RENDER: 1.0x
NO RELATED
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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.