Genuine 1987 Audi 4000 Starter

1987 Audi 4000 Starter Parts and Q&A

• Q: How to properly dismantle and reassemble the Starter components while ensuring all parts are cleaned, inspected, and replaced as necessary on 1987 Audi 4000?

  A: Mark the housings and mounting bracket in relation to each other, then remove the nuts and washers to withdraw the end mounting bracket. Next, take out the screws to extract the small end cover and gasket, followed by the circlip and shims, noting the exact number of shims as they determine the shaft endfloat. Unscrew the through-bolts to remove the commutator end bearing housing, then lift the brush springs to extract the field winding brushes. Note the position of the brush holder plate in relation to the field winding housing before withdrawing the plate from the armature. Unscrew the nut to disconnect the field wire from the solenoid, then remove the field winding housing from the armature. Unscrew the three bolts to detach the solenoid from the drive end housing and unhook the core from the lever. Unscrew and remove the lever pivot bolt, then prise out the lever cover pad. Remove the armature from the drive end housing and disengage the lever from the pinion drive. Use a metal tube to drive the stop ring off the circlip, extract the circlip, and pull off the stop ring before withdrawing the pinion drive from the armature. Clean all components in paraffin and wipe dry, examining them for wear and damage, checking the pinion drive for damaged teeth and ensuring the one-way clutch rotates in one direction. If the shaft bushes are worn, remove them with a soft metal drift and install new bushes that have been soaked in hot oil for approximately five minutes. Clean the commutator with a rag moistened with a suitable solvent, removing minor scoring with fine glasspaper, while deep scoring may require the commutator to be skimmed in a lathe and undercut, a task best left to a specialist. Measure the length of the brushes, and if they are less than the minimum specified, fit new brushes by crushing the old ones to free the copper braid, filing off excess solder, and soldering new brushes onto the braid using radio quality solder and a heavy-duty soldering iron. Ensure the brushes move freely in their holders and dress them with a fine file if necessary. Reassembly is the reverse of dismantling, taking care to fit the brush assembly over the commutator by either hooking the brush springs onto the edge of the brush holder or bending wire to hold the springs off the brushes until the assembly is fitted. Once fitted, release the brush springs to position them on the centers of the brushes, apply a little molybdenum disulphide grease to the splines of the pinion drive, fit a new circlip to the pinion end of the shaft ensuring the groove is undamaged, and remove any burrs with a fine file while applying sealing compound to the indicated points during reassembly.