This is Gary Schweitzer's...
This is Gary Schweitzer's Autolite starter from his '65 World's Fair Magic Skyway Mustang convertible. It's rusty from a tough Michigan climate (remember, Gary's 35,000-mile convertible was driven for 13 years in all kinds of weather). CAE is going to make it like new. We're using Scott Drake's AccuMatch OEM Detail Black finish to get Gary's starter case spot on.
Starters don't get much thought until we turn the key and nothing happens. Discount auto parts stores still offer rebuilt Autolite or Motorcraft starters for classic Mustangs because they were in production until the early 1990s. That gives us lots of cores to play with. And that's the easy part if you're not concerned with originality and can live with something right off the shelf. However, if you want your Mustang's starter to remain original in appearance, it's a matter of locating and rebuilding the correct starter for your application. Mustangs Etc. in Southern California has plenty of usable cores to choose from for restoration projects.
There are two basic Ford starter types - two-bolt and three-bolt. Small-block Fords like the 260, 289, 302, 351W, and 351C got two-bolt starters. The 170 and 200ci sixes, along with the FE-series 390, 427, and 428 big-blocks, got three-bolt starters. Drive gear housings vary depending upon flywheel/flexplate size, bellhousing type, manual or automatic transmission, and engine.
Disassembly begins with removal...
Disassembly begins with removal of the brush cover band. Gary's starter will get a new one, which is authentic in appearance.
We've long subscribed to the idea of buying a starter from a discount auto parts store and swapping the guts into the correct starter housing along with replacing brushes and bushings. It's easy, but not always the best choice. When we asked Garrett Marks at Mustangs Etc. where he was getting his starters rebuilt, he referred us to Bob Antounian at CAE, Inc. Quality Remanufactured Starters & Alternators in Van Nuys, California.
Think of CAE, Inc. as a custom starter/alternator/generator building shop where you can get just about anything you want for classic and late-model Mustangs alike. CAE will rebuild your starter, alternator, or generator and detail it to its proper appearance. Basic rebuilds are affordable and on a par with discount houses. Metal replating or the use of new parts is additional. It is an excellent value regardless of cost.
The starter drive cover is...
The starter drive cover is removed next. Bob Antounian at CAE Inc. will pop this guy into his parts tumbler for outstanding results.
Cast aluminum parts aren't media blasted and painted with aluminum paint. Instead, they go into a parts tumbler that gets them looking like new. Ditto for steel such as fasteners and other hard parts.
The four brushes, retained...
The four brushes, retained with springs, are removed from the brush end plate. Starter failure is sometimes caused by worn and contaminated brushes, which compromise continuity.
Use a 7/16-inch socket to...
Use a 7/16-inch socket to remove the pair of fine-thread bolts that hold the starter together.
The drive housing and brush...
The drive housing and brush end plate are separated from the starter housing.
The armature and starter drive...
The armature and starter drive are removed next.
The starter drive is removed...
The starter drive is removed from the armature once the retainer clip has been removed. Starter drive replacement is always suggested. Inspect the old starter drive for evidence of poor engagement (chipped teeth).
Clean up the armature and...
Clean up the armature and inspect it for good continuity by checking resistance. All elements of the armature must conduct electricity and offer a complete circuit to provide starter maximum torque. If good continuity isn't found, the armature must be repaired or replaced.
Elements are soldered to get...
Elements are soldered to get good continuity, which is all any rebuilder does with armatures. If an armature is found to be defective (won't conduct electricity), it is replaced with new or a salvageable used one.
The armature slipper is dressed...
The armature slipper is dressed to a clean, conductive surface, then checked for conductivity and run-out. Shafts are dressed and polished for smooth operation.
All CAE starters get new brushes,...
All CAE starters get new brushes, bushings, and drives. Autolite/Motorcraft starters have four brushes.
The new starter drive (also...
The new starter drive (also called a Bendix) is slipped onto a well-lubed shaft for smooth, predictable operation and retained with a shaft end clip.
All four brushes are replaced...
All four brushes are replaced and attached by screws as shown. Screws should be clean and securely tightened for good current flow.
New shaft bushings are pressed...
New shaft bushings are pressed in. This is the brush end cap with four brush holders getting a new bushing. Each has a spring retainer to hold its brush against the armature slipper. The drive housing (other end) also gets a new bushing. Bushings get a dose of molybdenum grease, which handles high temperatures quite well. Don't overdo the grease; use just enough to provide a lubrication wedge without getting all over the starter brushes and slipper.
Starter assembly begins by...
Starter assembly begins by installing the armature (also called a commutator), then the drive gear housing shown here. The mechanism on top is the starter actuator drive lever. When you turn the key to "start," it energizes the starter winding, which creates a magnetic field to draw this lever toward the winding, moving the starter drive into the flywheel/flexplate ring gear. The drive return spring returns the drive to rest when you release the key.
The brush end cap is fitted...
The brush end cap is fitted and bolts installed. Carefully fit both ends and check for proper fit. Make sure both ends are indexed properly.
Four brushes are installed...
Four brushes are installed and retained via spring-loaded holders. Keep your fingertips off the brush contact surfaces. Skin oil can hinder continuity.
CAE installs a new brush cover...
CAE installs a new brush cover band and starter drive cover. Purists will see the difference, especially in the drive cover. CAE can restore your original starter drive cover and band, which involves replating.
Gary's three-bolt Autolite...
Gary's three-bolt Autolite starter has been professionally rebuilt, inspected, and tested.