Manual

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37MT, 41MT and 42MT STARTERS 12V and 24V SEMI-SOLID LINK SOLENOID INSTALLATION

INSTRUCTIONS

WARNING!!!!ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL

REPAIRS TO A VEHICLE – INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO

THE DELCO REMY STARTING MOTORS. FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO

SERIOUS AND PERMANENT EYE DAMAGE.

Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are

beyond your technical capabilities should be handled by a professional installation specialist.

NOTICE! FOLLOW ENGINE AND/OR VEHICLE MANUFACTURERS INSTRUCTIONS CAREFULLY WHEN

REMOVING AND INSTALLING THE STARTERS.

These instructions describe the removal process for 37MT, 41MT and 42MT Conventional and Semi-Solid Link

Solenoids and the installation procedures for Semi-Solid Link Solenoids.

IMPORTANT: THIS PACKAGE INCLUDES TWO NEW MOTOR TERMINAL CONNECTOR STRAPS TO

REPLACE THE ONES ON THE STARTER]. ONE STRAP IS COMMON TO THE 37MT & 41MT AND THE

OTHER IS FOR 42MT ONLY. IT IS IMPORTANT TO USE THE CORRECT STRAP AS LABELED [See

illustrations, page 4]. THE STRAPS ON NEWER STARTERS MAY BE THE SAME AS THESE IN PACKAGE.

Determine the series of starting motor and solenoid type you are replacing. The motor series number is

stamped in the Series Block on the starter name tag and the solenoid part number is stamped on the

metal case of the solenoid.

 Conventional solenoid part numbers will be 1115657 or lower (Follow instructions A)

 Semi-solid link solenoid part numbers will be 1115663 or higher (Follow instructions B)

Fasteners, in this document, are referred to by wrench size rather than thread size.

DANGER!!! Before replacing the solenoid, the starting motor must be removed and completely disconnected

from the vehicle. Disconnect the negative (-) battery cable before removing the starter electrical connections.

A. CONVENTIONAL SOLENOID REMOVAL INSTRUCTIONS (See illustrations pages 3 & 4)

1. For older 42MT models, loosen 3/4” nut on solenoid motor terminal [1]. For 37MT, 41MT and newer 42MT

starters, loosen E8 Torx Head motor terminal screw [1*].

2. Remove E8 Torx Head screw [2] at field connection on starter frame.

3. For older 42MT models, remove 3/4” nut from solenoid motor terminal [1]. For 37MT, 41MT and newer

42MT starters, remove E8 Torx Head solenoid motor terminal screw [1*].

4. Remove solenoid to motor field connector strap [3]. Dispose of old design connector strap.

5. For insulated models (flexible ground cable not shown), remove top 3/8” nut and washer assembly from

ground terminal [5] of solenoid.

6. Remove flexible ground lead (not shown) from the solenoid ground terminal [5].

7. Remove three E8 Torx Head solenoid mounting screws [6].

8. Remove solenoid [7] from lever housing. Plunger and boot assembly [9] will remain on starter.

9. Remove access plug and gasket [4] from front of lever housing, ensuring gasket is removed.

10. Remove 1/2” plunger nut [8], carefully so it does not drop into starter, while holding the plunger securely

to prevent rotation. Dispose of nut [8].

11. Remove plunger and boot assembly [9].

Instruction Sheet

10512652

17DE04 REV 0

Summary of content (4 pages)

PAGE 1
Instruction Sheet 10512652 17DE04 REV 0 37MT, 41MT and 42MT STARTERS 12V and 24V SEMI-SOLID LINK SOLENOID INSTALLATION INSTRUCTIONS WARNING!!!!ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE – INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY STARTING MOTORS. FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE. Only perform the mechanical functions that you are properly qualified to perform.
PAGE 2
B. SEMI-SOLID-LINK SOLENOID REMOVAL INSTRUCTIONS (See illustrations pages 3 & 4) 1. For older 42MT models, loosen 3/4” nut on solenoid motor terminal [1]. For 37MT, 41MT and newer 42MT starters, loosen E8 Torx Head solenoid motor terminal screw [1*]. 2. Remove E8 Torx Head screw [2] at field connection on starter frame. 3. For older 42MT models, remove 3/4” nut from solenoid motor terminal [1]. For 37MT, 41MTand newer 42MT starters, remove E8 Torx Head solenoid motor terminal screw [1*]. 4.
PAGE 3
7. 8. 9. 10. 11. b) Adjust 1/2" plunger nut [8] to obtain correct distance between the pinion face [13] and the inside of the machined surface of the nose housing [14]. This distance must conform to the product specifications in order for the starter to function properly. While measuring, apply slight pressure against the pinion [13] to take the slack out. i. On 37MT models, the required distance is between 0.01" and 0.07". ii. On 41MT models, the required distance is between 0.15" and 0.21". iii.
PAGE 4
37MT, 41MT, & 42MT STARTING MOTOR ILLUSTRATIONS 37MT & 41MT CONNECTOR STRAP 42MT CONNECTOR STRAP SEMI-SOLID LINK SOLENOID 4