1997 Ford Pickup F150

STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

STARTER - DIESEL

1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

DESCRIPTION
The starter used on the 7.3L turbo diesel engine uses internal gear reduction and an externally mounted
solenoid. System consists of a starter (ignition) switch, starter relay, batteries, and wiring.

ADJUSTMENTS
PINION GAP

1. Secure starter in vise. Connect a switch in series with starter solenoid and battery. Connect second switch
in series with starter field wire. See Fig. 1 .
2. Turn both switches on. Starter drive should extend and motor should run. Turn switch No. 2 off. Starter
should stop running, but drive pinion should remain extended. With the drive pinion extended, measure
gap between pinion and stop ring.
3. Pinion gap should be .004-.079" (0.10-2.00 mm). If adjustment is required, insert or remove shims
between solenoid and drive end housing. Add shims to decrease gap, or remove shims to increase gap.

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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

Fig. 1: Measuring Pinion Gap

Courtesy of FORD MOTOR CO.

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL

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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

INFORMATION.

ON-VEHICLE TESTING

CAUTION: Before testing starter, ensure transmission is in Park on A/T models, or in

Neutral on M/T models.

STARTER MOTOR TEST

1. Ensure batteries are fully charged and in good condition. Ensure battery cables and connections are in
good condition. Measure voltage at starter solenoid battery cable terminal. If voltage is battery voltage, go
to next step. If voltage is less than 12 volts, recheck battery cables and connections. Service as necessary.
2. Connect one lead of remote starter switch to battery cable terminal on starter solenoid. Connect remaining
lead to "S" terminal on starter solenoid. Operate remote starter switch. If engine does not crank, repair or
replace starter. If engine cranks normally, starter is okay; go to STARTER RELAY TEST. If engine
cranks sluggishly, inspect batteries, cables, and connections. Repair or replace starter if batteries, cables,
and connections are okay.

STARTER RELAY TEST

NOTE: Perform STARTER MOTOR TEST before performing STARTER RELAY TEST.

1. Disconnect wire from terminal "S" of starter relay, located behind right battery. Connect remote starter
switch between terminal "S" and positive battery terminal. Ensure transmission is in Park on A/T models,
or in Neutral on M/T models.
2. Attempt to crank engine with remote starter switch. If engine cranks, relay is okay. Inspect ignition
switch, neutral or clutch switch, and circuitry for open or loose connections. If engine does not crank,
replace relay.

SOLENOID TEST

With all solenoid wiring disconnected, test for continuity between terminals. See SOLENOID
SPECIFICATIONS TABLE. Inspect contact plate for excessive pitting. Repair or replace as necessary.

SOLENOID SPECIFICATIONS
Terminals Ohmmeter Reading
"S" & "M" Continuity
"S" & Ground Continuity
"B" & "M" No Continuity

BENCH TESTING
NO-LOAD TEST

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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

1. Secure starter in vise. Verify pinion gap is correct. See PINION GAP under ADJUSTMENTS. Connect
jumper lead between battery positive post and solenoid terminal "B". Connect remote start switch
between battery positive post and solenoid terminal "S". See Fig. 2 .
2. Starter should rotate at a smooth, consistent speed. If rotation is not smooth, verify shim adjustment for
armature-to-starter housing clearance is correct. If shim adjustment is okay, replace starter.

Fig. 2: Testing Starter No-Load Operation

Courtesy of FORD MOTOR CO.

ARMATURE OPEN CIRCUIT TEST

An open armature circuit can often be detected by inspecting the commutator for evidence of burning. If
burning exists, replace armature. Inspect for damage to other related components.

ARMATURE GROUNDED CIRCUIT TEST

Connect voltmeter leads to negative battery terminal and starter commutator. Connect jumper cable to positive
battery terminal and armature. See Fig. 3 . If meter indicates any voltage, windings are grounded.

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Monday, May 11, 2009 6:35:11 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.
 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

Fig. 3: Testing Armature For Ground

Courtesy of FORD MOTOR CO.

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.

REMOVAL & INSTALLATION

Removal

Disconnect negative battery cable. Raise vehicle. Disconnect battery cable from starter. Disconnect starter
solenoid wiring. Remove starter mounting bolts or nuts. Remove starter from vehicle.
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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

Installation

1. Position starter assembly onto flywheel housing. Start bolts. Hold starter against mounting surface, fully
inserted into pilot hole. Tighten bolts or nuts to specification. See TORQUE SPECIFICATIONS .
2. Connect battery cable and solenoid wiring to starter. Tighten to specification. Lower vehicle. Connect
negative battery cable. Check starter operation.

OVERHAUL

NOTE: Use illustration for exploded view of Motorcraft starter motor assembly. See Fig.
4.

Adjust pinion gap upon reassembly. See PINION GAP under ADJUSTMENTS.

Fig. 4: Exploded View Of Starter

Courtesy of FORD MOTOR CO.

STARTER SPECIFICATIONS
STARTER SPECIFICATIONS
Application Specification
Brush Length
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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

3.0" (78 mm) Motor .66" (16.8 mm)

3.4" (85 mm) Motor .71" (18 mm)
Brush Spring Tension
3.0" (78 mm) Motor 64 ozs. (2.3 kg)
3.4" (85 mm) Motor 122 ozs. (3.5 kg)
Commutator Runout (1).005" (.12 mm)
Pinion Depth Gap .004-.079" (0.10-
2.00 mm)
Starter Load Test
Normal Load Current Draw
3.0" (78 mm) Motor 130-220 Amps
3.4" (85 mm) Motor 230-630 Amps
Maximum Load Current Draw
3.0" (78 mm) Motor 800 Amps
3.4" (85 mm) Motor 2400 Amps
Starter No-Load Test
Maximum Current Draw
3.0" (78 mm) Motor 60-80 Amps
3.4" (85 mm) Motor 170 Amps
(1) Replace armature if runout exceeds specification.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Starter Mounting Bolts 15-20 (20-27)
INCH Lbs. (N.m)
Brush Holder Bolts 18-27 (2-3)
Solenoid Screws 44-62 (5-7)
Solenoid Terminal Nuts
"M" Terminal 89-106 (10-12)
"B" Terminal 80-124 (9-14)
Through-Bolts 71-89 (8-10)

WIRING DIAGRAMS

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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

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 1997 Ford Pickup F150
STARTER - DIESEL 1997 STARTING & CHARGING SYSTEMS Ford Motor Co. - Starters - Diesel Engines

Fig. 5: Starter System Wiring Diagram

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