Remy 39MT HD - Manual

Instruction Sheet
10527276
15JL13 C/P30500 REV2
NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
©
2012 Remy International, Inc. All rights reserved 1
29MT - 38MT- 39MT HD STARTER REPLACEMENT PARTS INSTRUCTIONS
These instructions explain how to replace frame & field assemblies, commutator end cover assemblies and various components from
these assemblies.
NOTE: It is beneficial and possibly necessary to obtain one of these hardware packages for reassembly of the starter. It is
preferable to use new, undamaged parts.
WARNING!!! ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE –
INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY STARTING MOTORS.
FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE.
Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical
capabilities should be handled by a professional installation specialist.
FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING
THE STARTER.
DISASSEMBLY PROCEDURES
DANGER!!! ALWAYS DISCONNECT BATTERY GROUND BEFORE REMOVING OR REPLACING CABLES AT THE STARTER.
FAILURE TO DISCONNECT THE BATTERY GROUND CABLE CAN LEAD TO SERIOUS INJURY.
REFERENCE: There are exploded parts views of 29MT, 38MT & 39MT starters for easy reference on page 2. More detailed exploded
views can be found on the www.delcoremy.com website under products and service parts.
1. Remove vehicle leads connected to the starter, noting their positions for reinstallation of starter.
2. Remove the Jump Start Protection Shield (JSP), if it has this feature, and the solenoid motor terminal Lead.
3. Remove the nut on the motor terminal to release the field coil lead and the two (2) Thru-Bolts.
4. 39MT - Remove the ground (-) terminal assembly (nuts-2, washers-2, insulator-1), solenoid ground lead, brush holder assembly
(nut-1, washer-1, insulator-1) and retainer on optional over crank protection connector, carefully noting parts orientation for
reassembly.
5. 29MT & 38MT - Remove the two (2) brush holder screws and Commutator End Housing (CE) assembly.
6. 39MT - Remove the CE housing, two (2) o-rings from each brush holder terminal, insulation plate and spacer.
7. Remove the frame & field and brush holder assembly.
8. Separate the assemblies by removing the two positive (+) brushes from the brush holder assembly.
9. Remove the armature assembly.
10. Remove the pole shoe screws (8), pole shoes (4), field coil assembly and insulation strip between coils and frame.
REASSEMBLY PROCEDURES
1. Install field coil assembly into the frame, install the pole shoes (4), apply Three Bond 1401B-4 PLC or equivalent Loctite to screws,
install and loosely tighten the pole shoe screws (8).
2. Install the insulation strip between coils and frame, as removed and torque the pole shoe screws (8) to 30.6-51.0 Nm (23-38 lb ft),
insuring clearance for the armature.
3. Install o-rings on each frame end and o-rings (2) on the battery terminals. 39MT- Install o-rings (2) on brush holder terminal.
4. Reassemble brush holder assembly, by reinstalling the positive brushes (2).
5. Reassemble armature assembly or install new armature assembly.
6. Install alignment pin and brush holder & frame assembly, ensuring notch in frame is over the housing alignment pin.
7. Install field coil lead, as removed, to the Solenoid Motor terminal and torque nut on 38MT & 39MT to 15.7-18.6 Nm (12-14 lb ft) and
the 29MT to 7.3-9.3 Nm (65-82 lb in).
8. Install the Jump Start Protection Shield, if it has this feature, and torque the shield nut to 2.0-2.5 Nm (18-22 lb in).
9. Reinstall CE end housing (39MT) or housing assembly (29MT & 38MT).
10. Apply Loctite to Thru-bolts threads (2), install and torque to 7.7-9.8 Nm (68-87 lb in).
11. 39MT Starters
–Reassemble ground terminal parts, brush holder terminal fasteners and retainer on optional over crank protection
connector. Torque the ground terminal nut to 24.5-27.5 Nm (18-20 lb ft) and the brush holder fastener assembly nut to 7.0-11.0 Nm
(62-97 lb in).
12. 29MT & 38MT Starters –Reinstall brush holder screws (2) and torque to 2.4-3.0 Nm (21-26 lb in).
13. Reattach leads to starter ground (-) terminal, if it has one, and torque nut to 24.5-27.5 Nm (18-20 lb ft).
14. Reconnect the negative (-) cable at the battery.