Disassembling and assembling the starter (Peugeot 306)

Below is a more detailed description of work with the Bosch starter, which is installed on most cars. Figure 316 shows the installation drawing of this starter.

Figure 316. The arrow indicates the starter drive retaining ring. First, you need to knock down the tide ring.

Loosen the screws on the front side of the traction relay and, to remove the relay, disengage the starter drive engagement lever.
Unscrew and remove the cover from the rear of the starter.
Unscrew the manifold bearing cover bolts.
Use a screwdriver to press the locking bar from the end of the armature shaft, remove the small parts and pull the cover off the starter. If necessary, use a screwdriver to pry the cover open. Save the inserted washers.
Remove both carbon brushes from their mounts and remove the brush holder.
Remove the housing with the stator windings.
Remove the starter drive engagement lever support pin and take out the lever.
Remove the gasket from the bearing shield, remembering its installation position.
The stator winding brushes are soldered to the windings and can only be replaced together with the windings when replacing the entire coil. When making this replacement, the following work must be performed:

Loosen the four pole piece screws by tapping their slots with a brass rod as shown in Figure 317.

Figure 317. Loosening the pole piece screws with a brass rod.

Remove the pole pieces and release the winding with brushes from the pole pieces.

When removing the anchor or starter gear, use Figure 318:

Figure 318. Assembly drawing of the Bosch starter.

Knock down the thrust ring with a piece of pipe of the appropriate diameter to release the retaining ring indicated by the arrow in the figure.
Remove the retaining ring from the groove of the armature shaft.
Remove burrs from the end of the armature shaft.

Clamp the anchor in a vice and pull the drive gear off the anchor shaft as shown in Figure 319. Clean with gasoline (except for the stator winding, if it will be reinstalled) and check all the details. Check the anchor for burnt turns and the commutator for smooth surface. The collector can be processed with fine sandpaper, but a heavily worn collector is turned on a lathe while maintaining the minimum permissible diameter. A service station can do this work or recommend replacing the starter.

Figure 319. Removing the starter drive gear from the armature shaft.

The starter gear cannot be disassembled and must be replaced if damaged.

The starter is assembled in reverse order. It should be noted that the minimum permissible length of carbon brushes is 13 mm. When replacing brushes, crumble the old brush with pliers and clean the brush current lead. Insert the current lead into the new brush and flatten it on the other side. Press the bottom side of the current lead with tweezers and solder its top side.

The following points should be especially taken into account:

Slide the starter gear onto the shaft, put on the thrust ring and install a new retaining ring on the shaft. Place the thrust ring on the press table (Figure 320) and press the spacer ring into the thrust ring, applying press force to the armature shaft.
If the bushing in the manifold shield needs to be replaced (it can simply be pressed out), the new bushing should be pressed in after preheating the bearing cap for 5 minutes in hot oil.
When installing the traction relay, ensure normal engagement of the pusher with the starter drive engagement lever.
Cover the areas indicated in Figure 321 with sealing compound.

Figure 320. Pressing the thrust ring over the anchor shaft retaining ring.

Figure 321. Before assembly, cover the areas marked with letters with sealing compound.

The permissible axial play of the anchor is 0.1 - 0.3 mm, which can be adjusted by changing the thickness of the compensating washers installed between the end of the sleeve in the collector cover and the C-shaped lock washer.

Ducellier starter

The installation drawing of this starter is shown in Figure 322; it can be used in dismantling work. When replacing the brushes, they must be unsoldered. To do this, you have to remove the anchor and the cover.

Figure 322. Ducellier starter assembly drawing.

Further disassembly is carried out as follows:

Remove the two long bolts in the middle of the cover and remove the cover. Pay attention to the correct installation of washers.
Remove the starter housing.
Knock out the pin from the starter drive engagement lever. The pin is knocked out from right to left when looking at the end of the starter drive.
Remove the anchor from the drive bearing shield. Immediately check the condition of the anchor. Wipe the collector with a rag soaked in gasoline, being careful not to let gasoline get on the winding. If the collector is very dirty, it can be treated with fine sandpaper. The skin should not be used in this case.
If there are burnouts on the collector, it can be ground down. This work should be entrusted to a service station, since it is necessary to maintain the minimum permissible collector diameter.
Saw slots in the starter lamellas with a thin file to a depth of 0.5 mm.
Check the movement of the starter pinion and replace the pinion if necessary. To do this, remove the retaining ring from the armature shaft after using a piece of pipe of the appropriate diameter to move the retaining ring towards the armature, as described for the Bosch starter.
Check the carbon brushes and replace them if necessary. As already mentioned, they must be unsoldered from the windings when replaced.
Lubricate the front bushing before assembly.
Install the anchor and traction relay into the drive bearing shield. The support pin of the starter drive engagement lever is driven in from the left side of the shield.
Fill the rear bushing with grease and put on the cover. Ensure proper engagement of the springs.
When securing the cover, place the washers in the same order and tighten the bolt. The starter overrunning clutch does not require adjustment.
Install both tie bolts.