TSB : Disassembly And Ressembly

Details

Disconnect the M-terminal (B) on the starter solenoid assembly (A). Fig 1: Identifying Starter Solenoid Assembly & M-Terminal Courtesy of KIA MOTORS AMERICA, INC. After loosening the screws (A), detach the starter solenoid assembly (B). Fig 2: Identifying Starter Solenoid Assembly & Screws Courtesy of KIA MOTORS AMERICA, INC. Loosen the through bolts (A). Fig 3: Identifying Starter Bolts Courtesy of KIA MOTORS AMERICA, INC. Remove the brush holder assembly (A), yoke (b) and armature (C). Fig 4: Identifying Brush Holder Assembly, Yoke & Armature Courtesy of KIA MOTORS AMERICA, INC. Remove the lever plate (B) and lever packing (A). Fig 5: Identifying Lever Packing & Lever Plate Courtesy of KIA MOTORS AMERICA, INC. Remove the packing (A) and shield (B). Fig 6: Identifying Packing & Shield Courtesy of KIA MOTORS AMERICA, INC. Disconnect the planet gear (A). Fig 7: Identifying Planet Gears Courtesy of KIA MOTORS AMERICA, INC. Disconnect the planet shaft assembly (A) and lever (B). Fig 8: Identifying Planet Shaft Assembly & Lever Courtesy of KIA MOTORS AMERICA, INC. Press the stopper (A) using a socket (B). Fig 9: Pressing Stopper Courtesy of KIA MOTORS AMERICA, INC. After removing the stop ring (A) using stop ring pliers (B). Fig 10: Removing Stop Ring Using Stop Ring Pliers Courtesy of KIA MOTORS AMERICA, INC. Disconnect the stopper (A), overrunning clutch (B), internal gear (C) and planet shaft (D). Fig 11: Identifying Stopper, Overrunning Clutch, Internal Gear & Planet Shaft Courtesy of KIA MOTORS AMERICA, INC. Reassembly is the reverse of disassembly. NOTE: Using a suitable pulling tool (A), pull the overrunning clutch stopper (C) over the stop ring (B). Fig 12: Pulling Overrunning Clutch Stopper Courtesy of KIA MOTORS AMERICA, INC.