Okay, here's the pics. After getting it back together and cleaned up it was time to spend some time with the kids. So, without further delay, here's the rebuild/cleanup.
Starting off was quick and easy, I had the starter out in about 10 minutes.
But, that was where the fun stopped. Trying to remove the feed wire from the solenoid caused the solenoid to break apart. All well, can't fix that part.
Come to find out, I couldn't get the solenoid off without taking the housing apart, as one of the screws was causing me problems. So, quick inspections begin.
Armature is good. No arcs or extreme wear.
Teeth are all good. A bit of metal dust and old grease, but serviceable.
This is the screw that gave me problems. Phillips stripped out, square drive stripped out, Dremel and standard screw driver prevailed, but only just.
Brushes look surprisingly nice.
Actually, they look too good. This starter must not be that old.
I really didn't do much to it. It seems like a really really new starter, I've only had the truck for close to 10K miles. I replaced a couple of bearings, and the shift lever, as they came in the kit. I'm keeping the brush set for a later day. It would have been more work than necessary on otherwise good brushes. It can be done with a little patience and a soldering gun though.
Here's the nee shift lever on the left of the old lever. The new one seemed a little beefier in the contact spot, which is the sole reason I changed it.
I did a quick sand on the armature just to give a nice fresh face. 320 grit, made it look pretty. Cleaned everything up with Simple Green and contact cleaner. Conservatively greased the teeth, and got it all bolted together.
There are proper ways of doing the following, this does not fall into that category. I just wanted to see if I could make it work, and I did. I used a socket to spread the brushes, then just slid the armature right into place with minimal manipulation or headache.
Got it all bolted back together and brought some rags to the trash. I almost stepped on this little guy. He was chilling in the driveway right next to my tire.