Starting System: Service and Repair

Starter Pinion Clearance Check





1. Remove the lower flywheel housing cover.
2. Inspect the flywheel for signs of unusual wear such as chipped or missing gear teeth or the flywheel being bent.
3. Start the engine and gently touch the outside diameter of the rotating flywheel ring gear with chalk or crayon to show the high point of tooth runout after the engine is turned off. Turn the engine off and rotate the flywheel so the marked teeth are in the area of the starter pinion gear.
4. Disconnect the negative battery cable to prevent accidental cranking of the engine.
5. Measure the clearance between the top of the ring gear tooth and the bottom of the pinion tooth using the width of a wire gage or standard feeler stock. Normal clearance is 0.5 to 1.5 mm (0.02 to 0.06 in).




6. If clearance is less than 0.5 mm (0.02 in), and the starter whines after firing, shim the starter away from the flywheel.
Add 1.0 mm (0.04 in) shims, one at a time, to both long bolts between starter mounting pads and the engine until the noise problem is corrected. Do not use more than 2 shims total.
7. If the pinion clearance is more than 1.5 mm (0.06 in) and the starter whines during cranking, shim the starter toward the flywheel.
Add 0.33 mm (0.014 in) shims between the outboard starter mounting pad and the engine mount until the noise stops. Do not add more than 4 shims total.

NOTE: Refer to Fastener Notice in Cautions and Notices.

8. Install the mounting bolts.

Tighten
- Mounting bolts (diesel) to 45 N.m (33 lb ft).
- Mounting bolts (gas) to 40 N.m (30 lb ft).

9. Install the negative battery cable and test for noise.
10. Add or reduce the amount of shims if noise continues.