Removing and Reinstalling the Drive and Pinion From The Ford Diesel Starter F5TU-11000-AA REMOVING: Lock the drive end assembly in the vice with one edge of the solenoid opening over the jaw of the vice (leaving most of the solenoid hole between the opening of the jaws of the vice.) With a pair of pliers wide open, turn the jaws facing the floor— handles will be up. Insert one handle in the solenoid hole and wedge it be- tween the solenoid fork ring on the drive and the top of the planetary gear ring. Push down on the pliers and this should raise the drive to its highest position. Hold down on the pliers with your stomach (we use our stomach for a shelf, why not use it for a press?). Place an 18mm or a 3/4 inch socket over the lock ring collar and tap it with a hammer until the ring un- locks. Still holding the pliers with your stomach, use two very small blade screwdrivers to remove the locking ring. One screwdriver is placed on the locking ring on the opposite side from the opening in the ring. Tap this screw- driver with a hammer. This should raise the openings of the locking ring up slightly. While holding down on the first screwdriver, place the second screw- driver under the point of the lock ring opening and twist the second screw- driver back and forth until the locking ring is removed from the locking col- lar. REINSTALLING: Remove the drive clutch from the shaft as described in WAI technical update #30 (by re- moving the two retaining clips that hold the support plate to the drive shaft and rotating the drive while sliding it on the shaft. The drive should slide off). Place the drive fork on the drive clutch as- sembly and slide this assembly into the drive end bearing. Place an old low torque Delco armature in a vice with the comm end up. Place the drive end housing with the clutch assembly and drive fork still in place, on the top of the armature. This holds the end of the drive shaft at its highest position. Place the drive spring, pinion, locking collar and lock ring on the shaft. Hold down the pinion and slide the lock ring into position. Place a small set of two- legged pullers over the pinion so that the legs are on the bottom side of the pinion and the shaft of the pullers is on the top of the drive shaft. Tighten to place slight pressure on the locking ring. Use a small blade screwdriver and hammer to tap the locking ring into position. Readjusting the pullers sev- eral times will be necessary to hold proper pressure on the locking ring. The locking ring should snap into place, locking the pinion on the drive shaft. Remove this assembly from the vice, slide the shaft of the planetary gear into drive assembly and twist into locking position—be sure this is locked in place. Pull back on the planetary as- sembly and replace the two locks by use of needle nose pliers and taping with a screwdriver and hammer. Note: The pinion gear must be re- moved before removing the drive from the housing or the housing will be dam- aged. Now pat yourself on the back and take a break. You deserve it! I hope this will help someone. Quinton King is owner of King & Son Auto Electric, La Grange, GA. NOVEMBER, 1999 Page 1 of 1