Remy 50MT Conventional Solenoid and Plunger - Manual

Instruction Sheet
10533719
15OC12 DS06032 REV0
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
50MT™ CONVENTIONAL SOLENOID AND PLUNGER SERVICE KIT REPLACEMENT INSTRUCTIONS
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 FOR REPLACING THE CONVENTIONAL SOLENOID AND PLUNGER ASSEMBLY
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.
1. Remove vehicle leads connected to the starter (Including solenoid ground lead), noting their positions for reinstallation of
starter, and remove starter.
2. Remove solenoid-to-motor field connector strap or lead (for 32V/64V models).
3. Remove lead from solenoid ground terminal.
4. Remove the access plug and gasket from front of lever housing, ensuring gasket is removed.
5. Remove the four (4) solenoid mounting bolts and solenoid
6. Carefully remove the conventional solenoid plunger nut so it does not drop into the motor and dispose of it.
7. Remove plunger if replacing it.
REASSEMBLY PROCEDURES FOR REPLACING THE CONVENTIONAL SOLENOID AND PLUNGER
1. Install the conventional solenoid plunger, if replacing it, and the solenoid plunger adjusting nut thru the lever housing’s access
hole finger tight.
2. Install the conventional solenoid with four (4) mounting screws and torque to 14.13-21.47 Nm (125-190 lb-in).
3. Install ground lead to solenoid ground terminal on CE frame and torque nut to 27.12Nm (240 lb in).
DANGER!!!
Disconnect solenoid motor connector strap or lead (for 32V/64V models) to field terminal before adjusting
the pinion clearance.
After repair and reassembly, it is necessary before installation on the engine to check and adjust pinion clearance. (See
graphics, page 2).
4. Reinstall access plug and gasket in front of the lever housing and torque plug to a minimum of 8.1 Nm (72 lb in)
5. Reinstall solenoid-to-motor field connector strap or lead (for 32V/64V models).
6. Reinstall field terminal and solenoid motor terminal nuts finger tight.
7. Torque field terminal and solenoid motor terminal nuts to 27.12 Nm (240 lb in) (1.8-4.3 Nm for 32V/64V on solenoid side).
8. For
insulated models, remove the nut and washer assembly from solenoid ground terminal and install the flex ground lead.
Following these steps carefully is important for adjusting pinion clearance.
Proper care must be exercised when completing these steps to avoid personal injury and/or property damage. Also,
to avoid overheating and possible damage to the solenoid, power should not be applied in excess of one (1) minute.
♦ DANGER!!! Ensure the stamped metal connector strap is disconnected from the field terminal to prevent the
possibility of motor from rotating.
♦ Energize solenoid to prevent plunger from rotating and damaging the rubber boot while turning plunger nut to adjust pinion
clearance.
♦ Apply appropriate power (12V or 24V) to solenoid between the switch "S" (+) and “G” ground (-) terminals.
♦ Seat the plunger by simultaneously pushing on 1/2" plunger nut. Note: 24 volts can be obtained by connecting two 12V
batteries in series.
♦ Adjust plunger nut to obtain the pinion clearance 0.328”-0.390” from pinion face to housing face. (See graphics on page two)
♦ Remove power immediately after adjustment is completed.