Replacing Mitsubishi Starter Motor Brushes

[HOrnbrod]

I've done a ton of these in the past, but never the Mitsubishi starter our MJ's use, and I'm stumped. My starter was intermittent, so I pulled the starter apart and sure enough the old brushed were worn down to about 1/4" long. I replaced it with a new one, now I want to refurbish the old one for use a spare.

 

Since the brush leads are spot welded to the holder, the whole brush set and holder must be replaced as a unit, which is pictured below. The problem is I can't figure out a way to move all four brushes back enough to make room to slide over the armature commutator. I could remove the individual brush springs, but then once the commutator was in I'd have no room to replace the springs. There must be a trick for these starters to retract the brushes that I obviously don't know. The only thing I can think of is to use a tapered shaft to push through the opening closely followed by the armature commutator. Anyone installed a new brush plate in the Jeep starter motor?

[jimoshel]

Try using a cardboard around the armature to hold the brushes out. When the armature is started remove the cardboard. That sounds so simple that there is something I'm missing.

[HOrnbrod]

The way I used to do starters like this Jim is to push each brush back until the spring end can be seen on the outside, then slide a sheet metal shim between the spring and brush where the red line is below. This holds the brush out and is usually enough room to get the assembly over the commutator, then pull the shims. But there's a smaller diameter ball bearing in the way on top of the commutator at the end of the armature on these foolish Mitsu starters. I can get the brushes out far enough so go over the ball bearing, but can't get the damn brushes back another 1/4" to slip on to the armature commutator. And the spring tension is tremendous. It's starting to piss me off..........

[HOrnbrod]

Try using a cardboard around the armature to hold the brushes out. When the armature is started remove the cardboard. That sounds so simple that there is something I'm missing.

 

Way too much spring tension for cardboard Jim.

 

Well, I guess no one has been intimate with these starters before. Everyone just buys a new starter now. No problem - I'll figure it out.  :cheers:

[fiatslug87]

I have no idea but want to know how you will finally do it, which I know you will figure out.

[FrankTheDog]

Where did you get that part and what is it called. I have a bunch of used starters on hand and would like to try my hand at refurbing them.

[HOrnbrod]

On Ebay HERE. $8.50 shipped.

 

EDIT:  This part fits the end cap and the mounting holes line up, so it's definitely for a Mitsubishi PMGR model starter. However I just looked up the factory part number for the brush holder (83503671), and it shows only two brushes. The p/n for the other two brushes is 83503670. The Ebay brush holder I bought has all four brushes. Also the brushes on the factory brush holder do not appear to be as long as the Ebay aftermarket one. So maybe the Ebay part isn't correct for our Jeep Mitsubishi starter. I know there were variations for different applications. This could explain why I can't mount this unit over the commutator. I've done lots of starter brush holder plate replacements in the past and never had this problem.

 

So I'd hold off buying this unit Frank until I figure it out.

[FrankTheDog]

Ok, thanks. Will be interested on how you make out. I'd pull one apart myself right now but have a few to many irons in the fire as it is.

[jimoshel]

Won't be the first time I've got a part and it was't right.

[HOrnbrod]

THIS is the correct part, I'm sure of it. Comes with the brush plate with the 2 neg. brushes attached with the correct springs, and the 2 pos. brush assembly . Will order after I locate one a bit cheaper, and should have done my homework better.   :doh:   Will follow-up after I install.

[mikekaz1]

Hmm. Following this... never realized they were Mitsubishi sourced

[Jeepman]

I just slide a small Deep socket in there although Whenever I have replaced the brushes the new one came with a plastic sleeve already installed which makes it easy to slide in...

 

 

Oh and here is a cheap place to buy what your looking for...

http://alternatorstarterparts.com/

 

They have a repair kit for like $38

[HOrnbrod]

There's still a old starter/alternator shop in the next town so I stopped by this morning on the way to Lowes with my old Mopar brush assembly. He had both pieces in stock, "offshore" brand, and the part numbers crossed to the Mopar numbers in his book (83503671 Brush Holder & 83503670 Field Brush Assembly) and charged me $19 total. It was cake putting the new brush assembly in; didn't need a socket, just my fingers and they popped right on. Before reassembly I field stripped the starter and cleaned / degreased it, polished up the commutator, and lubed the gears and bearings. When bench tested through the solenoid, and it spun right up and ran smoothly. Good for another 25 years.  :)

 

And Jeepman, thanks for the parts link, nice site - bookmarked.  :cheers:

[gogmorgo]

Hmm. Following this... never realized they were Mitsubishi sourced

Mitsubishi is a HUGE conglomerate that has a hand in pretty well every industry, from banking to real estate to consumer electronics, appliances, cars, aviation, mining, nuclear power... everything. You've probably got a whole bunch of their products in your home, at least as components of other things. Not bad for a company that started out in shipping.

[HOrnbrod]

Meh. Mitsubishi Corp. is only #9 in Japan, and not even in the top 200 worldwide. Guess who's the #1 revenue generator?

 

 

Freakin' Walmart. 

[A-man930]

I've been toying with disassembling my starter (full of mud).  Glad I found this thread.

[schardein]

Good info.  I also have a collection of non-op starters.