Ford F3RZ-11002-ARM
Starter

Service and repair operations on the Zetec starter motor start with disconnecting both the battery ground cable and the Mass Air Flow (MAF) sensor electrical connector. The air cleaner removal process starts with disconnecting the breather pipe before extracting the air cleaner outlet tube which reveals the throttle body. The assembly ends with air cleaner separation from the throttle body. The next step involves disconnecting the upper bolts of the starter motor followed by vehicle elevation and suspension. Start by disconnecting the electrical connector of the starter motor before removing the starter unit. Reverse the steps of disassembly to reinstall the component.

Before starting starter motor service or repair the technician must separate the battery ground cable while unfastening the air cleaner. The first step includes removing the upper bolts from the starter motor while paying attention to the fact that the engine ground cable is attached to one of these bolts. First separate the cable ties and afterward lift the vehicle while providing support. The starter motor requires removing by disconnecting its electrical connectors before starter motor removal. The reverse procedure should be followed for assembling this component.

The procedure for fixing the starter motor starts with removing the battery ground cable. Next, remove the air cleaner. The starter motor upper bolts need removal while paying attention to the fact that the engine ground cable is fixed to one of the bolts. The maintenance procedure starts with cable tie cutting. Before the installation start the vehicle must be supported in the air to proceed with starter motor electrical connector removal and motor removal. Follow the opposite steps for installing the component after removal.

Base your starter motor service or repair by unplugging the M-terminal of the starter solenoid connector nut followed by disconnecting the starter solenoid. Follow these steps consequently by taking out the two through bolts to split the drive end housing from the starter frame and then disassembling the output shaft yet carefully saving the armature thrust ball between the starter motor armature shaft and the output shaft seat for reinstallation. Take the starter drive stop ring followed by the starter drive away from the output shaft before you extract the drive lever with its pin from the starter drive which requires the clip removal. Start with the armature thrust washer extraction by removing first the Truarc C-ring followed by the washer itself and subsequently remove the planet gear retainer to separate the output shaft from the stationary gear. You should first unscrew the bolts to remove the brush end plate and bushing before you can extract the starter motor armature from its starter frame by removing the brush holder and the armature. Begin assembly by taking off the brush holder cover to apply a thin layer of low-temperature grease according to Ford WSG-MIC218-B2 specification on each end of the armature shaft and its splines. Install the brush holder on the armature by placing it correctly while adding the springs. Return the brush holder cover before placing the starter motor armature into the starter frame while keeping the brush holder joined to the armature. After implementing the brush end plate with bushing you should connect the output shaft to the stationary gear prior to applying the planet gear retainer. After placing the armature thrust washer you need to apply the drive lever pin to the starter drive before fastening it with the provided clip. Based on installation sequence you must attach the starter drive to the output shaft before installing both the starter drive stop ring and then placing back the drive end housing into the starter frame. Secure the starter solenoid along with its positive brush connector nut to the M-terminal of the starter solenoid.

The ground cable from the battery needs removal before starting starter motor repairs. Next, remove the air cleaner. The starter motor upper bolts must be removed after noting that one of these bolts holds the engine ground cable. The starter motor electrical connector needs to be removed after supporting the vehicle at a raised position. The starter motor maintenance requires the removal of its lower bolt and subsequent starter motor removal. In order to install the starter motor follow the steps in reverse order to those used for removal. After disconnection then reconnection of the battery the vehicle undergoes an adaptive relearning process that produces abnormal driving symptoms which need driving for 10 miles (16 km) until the process completes.

Detach the brush holder and then the armature itself from the starter frame.

Remove the starter solenoid wire nut and tighten it to 5 Nm (44 lb-in) upon reinstallation.

Detach the power steering pressure line brackets from the stud bolts by removing the nuts, followed by removing the bolts to take out the starter motor.

Install them finger tight before final tightening.

Reverse the removal procedure.

Reverse the removal procedure.

Disconnect the battery ground cable.

Begin by disconnecting the battery ground cable.

Disconnect the battery ground cable.