G 2500 3/4 Ton Van V8-305 5.0L VIN M SFI (1997)
Starter Motor: Service and Repair
Pinion Clearance
NOTICE: Never operate the starter motor more than 15 seconds at a time without pausing to allow it to cool for at least 2 minutes. Overheating,
caused by excessive cranking, will damage the starter motor.
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. If the flywheel needs replacing.
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
run-out after the engine is turned off. Turn the engine off and rotate the flywheel 59 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. Engage the pinion to the flywheel and 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. Normal clearance is 0.5 to 1.5 mm (0.02 to 0.06 inch).
6. If clearance is less than 0.5 mm (0.02 inch) and the starter whines after firing, shim the starter away from the flywheel.
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Add 1.0 mm (0.04 inch) shims, one at a time, to both long bolts between starter mounting pads and engine until the noise problem is corrected.
Do not use more than 2 shims total.
Flywheel To Pinion Clearance
Shimming The Gas Engine Starter
7. If the pinion clearance is more than 1.5 mm (0.06 inch) and the starter whines during cranking, shim the starter toward the flywheel.
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Add 0.33 mm (0.013 inch) shims between the outboard starter mounting pad and the engine mount until the noise stops. Do not add more than
4 shims total.
8. When shimming is done, tighten the mounting bolts. Refer to "Fastener Tightening Specifications".
