Page G-4
MOTOR
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Dangers and Warnings.
Pull back each brush until each of the springs (15) rest
against the side of its brush (Ref Fig. 5 on page G-4).
Remove brushes and replace with new brush replace-
ment kit. Locate springs against the side of each brush.
Install terminals and brush plate using reverse order of
removal. Install armature (commutator end) through
brush plate and press into new bearing using moderate
heat to aid installation. Position brushes against commu-
tator. Ensure the springs are seated against the rear of
the brushes and are able to move freely.
Motor Assembly
Tool List
Qty. Required
Socket, 3/8", 3/8" drive ................................................1
Torque wrench, in. lbs., 3/8" drive ...............................1
Align the commutator end cover with the holes in the
motor housing and assemble (Ref Fig. 3 on page G-2).
Secure the commutator end cover to the motor housing
with bolts (2) and tighten to 90 in. lbs. (10 Nm) torque.
Attach ring magnet to armature shaft with screw. Install
inner snap ring in cover and insert speed sensor. Secure
with second snap ring (Ref Fig. 3 on page G-2).
Motor Tests
The motor housing is not available as an individual part.
No testing is recommended to determine the specific
area of failure. When a test of the power wiring system
indicates that the system is operating correctly and the
vehicle either does not run or runs poorly, the motor is
the only remaining component and must be replaced.
Motor Installation
Tool List
Qty. Required
Socket, 7/16", 3/8" drive ..............................................1
Torque wrench, in. lbs., 3/8" drive................................1
Be sure that a bumper spline is installed between the
motor input pinion shaft and splines. Apply a small quan-
tity of
molybdenum
grease to the
male
portion of the
spline. Carefully mate the motor spline with the input
shaft of the rear axle. Align the orientation marks and
install the mounting hardware. Tighten to 168 in. lbs. (19
Nm) torque (Ref Fig. 2 on page G-1).
Attach the four motor wires to motor (Ref Fig. 6 on page
G-4). Tighten the nuts to 66 in. lbs. (7 Nm) torque.
Tighten speed sensor magnet attachment screw (17) to
18 - 23 in. lbs. (2 Nm) torque (Ref Fig. 3 on page G-2).
Fig. 5 Securing Brushes
Brush
Brush
Spring
Spring Position
for Installed Brushes
Spring Position for
Removing/Replacing
Brushes
Brush
Fig. 6 Motor Wiring
Motor
Terminal
Wire
Marker
From
A1
A2
F1
F2
A1
A2
F1
F2
Controller "F1"
Controller F2"
Controller "B+"
Controller "M-"
MOTOR WIRING - PDS
