87-375-8 December 1998 SD205/255 Series Overview IN THIS ISSUE WE’LL TAKE a look at Delco SD205/255 starters, which were introduced in 1996 and are used on a long list of GM engines. We have identi- fied five different versions of this hybrid unit. It uses some 5MT-style parts, some SD210/260-style parts and some parts that are unique to the SD205/255 series. Look like 5MTs At first glance these starters appears to be SMTs. However, there are several differences. First, look for the brush-holder mounting screws on the field case, same as the SD210/260. You will also notice that the drive opening is smaller and that the D.E. housings have been beefed up more than most 5MT D.E. hous- ings. This should help prevent these housings from breaking (Figure 1). Brush-holder mounting screw Figure 1. SD205/255 starters have brush-holder mounting screws on the field case, like the SD210/260. Also, the D.E. housings have been beefed up, compared to SMTs. Unlike the SMT, SD205/255 units use a solenoid with an M8 x 1.25 battery terminal, 3/8-16 motor ter- minal and M5 x 0.8 switch terminal (OE #1114584, WAI #66-143). In addition, they have notches in the solenoid cap at the battery terminal so the battery cable can be installed in only one position. This prevents the cable from being routed incorrectly (Figure 2). When you remove the solenoid cap mounting screws, you will find an odd-size M4.5 x .75 screw. Notches Figure 2. Notches in the solenoid cap assure that . the battery cable can be “™ Brush-holder = installed in only one mounting screw position. These starters use a 5MT-style shift lever, except the shift lever has large buttons that are welded off center. To accommodate these large buttons, the starter drive has two large cups. Also the shift-lever pivot pin does not have a clip to retain it in the D.E. housing. Instead, the end is mushroomed over (Fig- ures 3 & 4). Note that the standard 5MT pivot pin and retaining clip can be substituted here. Starter drives for these units are OE #10487934 (WAI #54-167), which is a cushion drive, and OE #10487536 (WAI #54-166), which is not a cushion drive. No retaining clip _ 7 Large buttons & Figure 3. The shift-lever pivot pin does not have a clip to retain it in the D.E. housing. Instead the end is mushroomed over. SD255 units use armature #10471537 (WAI #61- 132), which is also used in one 5MT and one SD260 unit. It has bearings in both the drive and commutator ends. SD205 units use armature #10467708 (WAI # 61-139), which is also used in one of the SD210 starters. It has bushings in both drive and comm ends. | Wetherill Associates, Inc. 1101 Enterprise Drive — Royersford, PA 19468 800-877-3340 Care is taken to ensure the accuracy of information presented here, but Wetherill Associates, Inc., assumes no responsibility for possible errors. Copyright © 1998 Wetherill Associates, Inc. 6265 Technical Update 42 page 2 _ Hole forbreten eer mounting screw Brush-holder Hole for brush- holder mounting screw Two large cups Leather washer Figure 4. Brushes and brush holder are the same as the S$D210/260 series. There are two large cups on the drive to accommodate the larger buttons on the shift lever. Similarities to SD2 10/260 The SD205/255 units also have some similarity to SD210/260 units. First, the brushes and brush holder are the same as SD210/260 (Figure 4). Like the SD210/260, these units use two screws to mount the brush holder to the field case. The SD205/255 may also have either standard- torque field coils or high-torque field coils, like the SD210/260 series. The only difference in the field coils is the style of the motor terminal that comes out of the field case. For the SD210/260 this is a flexible lead with an eyelet terminal that fits over an M&8 x 1.25 motor stud on the solenoid, but for the SD205/255 this is a solid strap (like the SMT) with a small hole for a 10-32 screw to attach it to the motor terminal on the solenoid. Other features SD205 starters have bushings in the D.E. housing and C.E. frame, and SD255 units use needle bearings in the D.E. housing and C.E. frame. Notes Both SD205 and SD255 use a leather brake washer at the C.E. end (Figure 4). According to the bill of materials, the SD255 starter #10455065 (WAI # 2-1796-DR) has two dif- ferent thru-bolts. One thru-bolt (#1985150) is 135.5mm long and the other (#10467601) is 133.5mm long. Because there is only a 2mm difference in length, it’s easy to install these thru-bolts in the wrong posi- tion, which can cause a whole lot of aggravation. If the longer thru-bolt is installed in place of the shorter thru-bolt, it will extend into the cavity and will not Figure 5. One thru-bolt is 2mm _ shorter than the other, so be careful. If the longer thru-bolt in installed in the wrong place, it will extend into the cavity and prevent the starter mounting bolt from going through. allow the starter mounting bolt to go through (Figure 5). We have found that the shorter thru-bolt (84-1342) works well in both positions.