Some advice regarding those starter contacts. Just r+r,ed mine in my 95. 128k and man they were smoked. The one was paper thin and the plunger was pitted to no end. from what I read it well worth addressing before it takes out anything else and its so easy a monkey could do it. Thanks Larry B

 

Did you check the brushes while you had the starter out?

 

Good idea about the brushes. Also a good time to take everything apart, clean the armature, lube the gears and the bearing with the plastic cage in the reduction gear housing (use synthetic grease), and replace contacts and plunger.

Along with the brushes, your starter is now rebuilt. It's amazing how much build up gets on that armature. WD40 is a good cleaner for the armature. Just don't go crazy with the grease. Replace those stupid phillips screws with nice allen head bolts so it's easier next time. Use loc-tite on those, mine were loose. Kevin

 

undercut the armature commutator while you're at it, will produce higher torque. To do this, remove the mica insulation between the comm bars about 1/16" deep with a dremel and tiny cut-off wheel. Some armatures are already undercut, if so, make sure to clean the brush material from between the comm bars, otherwise they will short and reduce the starter's torque.

Chris