Starter Motor re-assembly

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blackfish

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Following on from my previous thread about the Lucas M45G starter motor, can anyone help with re-assembly technique please? The problem is this. Having cleaned everything up and checked the commutator and brushes, I now want to put the commutator end plate back on. It seems to me to be impossible to get the brushes (4 of them) over the commutator whilst they are under spring tension. If I re-assemble with the springs released it's then impossible to re-attach the springs. Catch 22 - or am I missing a trick somewhere here?
 
There is usually small holes in the end plate where you can stick a cocktail stick or similar thru to hold the brushes back while you assemble it.
Stu
 
No suitable holes I'm afraid. I can part the opposing brushes with a cocktail stick, but then I can't get the end of the armature shaft past them! More lateral thinking required I think!. I've tried to tie them back with bits of wire / string, but that's not working either. Do I need to remove the Bendix end of the arrangement somehow and re-assemble the brushes / commutator end whilst outside the casing?
 
A photo would help..........but are there 'any' holes / vents in the end housing? If there are, you could try wedging the brushes in their housings using the (tapered) ends of small cables ties.........then when it's all back together simply pull out the cable ties
 
Push the end plate onto its bearing surface,but not all the way. lift each spring in turn and fit brush then lower the spring until it jams on the side of the brush. when all four are like this, drop of engine oil on shaft then push the end plate home making sure the small peg is lined up. fit through bolts and tighten, lift spring and drop the brush fully home, job done. Did you remove the armature and the "Y" shaped bit a steel? if so you will need to adjust the throw of the pinion. The pivot bolt is eccentric and can be adjusted so that the pinion NEARLY touches the locking ring, failure to check make cause damage in the future.
 
Thanks to all for replies. Pampas, I think your method sounds most promising. I did pull the armature out of casing and have cleaned out the muck from around the field coils, but have not removed any other parts or tried to separate anything from the yoke, so I'm assuming it'll all just go back in the way it came out?
 
Pampas, the lateral pressure on the brushes from the springs was just the lateral thinking that was required. It's all back together again and I'll bolt it back on the engine tomorrow to see whether it's working. Thanks again.
 
you may find that its still not working properly as the solenoid piston may still have a load of muck around it, if you can, when fully assembled wing the pinion to its fullest position and everthing slides bask ok then you may be lucky. Many thanks for you comments, spent a few years overhauling most types of alt & starters. If you get stuck send a pm and will take it from there. Good luck with your tests.
 
Starter motor back on the boat and working. After priming the fuel system engine running today. All I need to do now is to finalise my stern tube extension and fit new stuffing box, clean up and launch sometime before the end of the summer (if it's not over already!). Thanks again to all for help proffered.
 
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