16108 Mercury STARTER ROPE

Be sure the air supply to the air starter is turned off.
TYPICAL EXAMPLE1. Remove tubes (1) from the starter drive assembly housing.2. Disconnect starter air inlet line at union (2).3. Fasten a hoist (not shown) to the air start motor. Remove three bolts (3) and remove the air starter. The weight of the air starter is 85 lb. (39 kg).
TYPICAL EXAMPLE4. Install a new gasket between the air starter and the flywheel housing. Install the air starter with three bolts (3) and lockwashers.5. Connect the starter air inlet line (2) to the air starter.6. Connect tubes (1) to the starter drive assembly housing.Disassemble Air Starter
start by:a) remove air starter Make sure there is a complete set of new gaskets, vanes, seals and O-ring seals before the air starter is disassembled. 1. Make a mark to show the position of housing assembly (1) respective to cover (2) for assembly purposes. 2. Remove the bolts that hold the housing assembly in position and remove the housing assembly from the cover.
Put drive housing (1) in an arbor press, piston end up. Apply force to drive assembly (4) to compress spring (5) before removing the retainer. Be sure spring (5) forces drive assembly (4) out of housing (1) while releasing the press. Failure to observe this procedure can result in personal injury.
3. Remove drive assembly (4), spring (5) and seat (3) from the housing assembly. 4. Remove plug (7), oiler and bushing (6) from housing (8).5. Disassemble the drive assembly as follows: a) Remove seal ring (9) from piston (10). b) Remove retainer (13) from the piston with tool (A).c) Slide the piston toward the gear end of clutch assembly (12). d) Remove spacer (14) and two shift rings (11) from the clutch assembly. Do not clean the clutch assembly in kerosene or other solvent.e) Remove piston (10) from clutch assembly (12). 6. Make a mark to show the position of cover (2) respective to the housing for assembly purposes. Remove the bolts that hold the cover in place. 7. Remove the cover with shaft assembly (16) and washer (17) from case assembly (15). 8. Remove the shaft assembly from the cover. 9. Remove seal (18) and O-ring seal (19) from the cover. Some air starters have a snap ring on top of seal (18) to hold the seal in place. Remove this snap ring before the seal is removed. 10. Remove gear (21) from shaft (20) with a press. 11. Remove key (22) and remove bearing (23) from the shaft with a press. 12. Make a mark to show the position of case assembly (15) respective to housing (24) for assembly purposes. Remove the bolts and nuts that hold case assembly (15) in position.13. Remove the case assembly from housing (24). 14. Remove needle bearing (25) from the case assembly. 15. Remove the lockwire, bolts and gear retainer (26) from the rotor. 16. Install gear retainer (26) in an up side down position on the rotor and install the bolts that hold it in place. Do not tighten the bolts completely.17. Install tooling (B) under gear (27) and remove the gear from the rotor. 18. Remove the bolts that hold cover assembly (28) on the opposite end of housing (24). 19. Remove the cover assembly with gasket (30) and rotor and cylinder assembly (29) from the housing. 20. Remove washer (31) from the plate bearing.21. Remove lock (32) from nut (33) and remove the nut from the rotor with tool (C). 22. Remove lock (32), plate (35), cylinder (34), dowel (38) and spacer (37) from rotor (36). 23. Remove bearing (39) from plate (35). 24. Remove four retainers (40) from the cylinder. 25. Remove five vanes (41) from the rotor. 26. Remove plate (42) from the rotor and remove bearing (43) from the plate. 27. Remove spacer (44) from the rotor.Assemble Air Starter
Clean all parts thoroughly. Put 2S3230 Bearing Lubricant on all bearings and the drive assembly. Put a thin layer of SAE 10W oil on all other parts before assembly. 1. Install spacer (1) and plate (3) on the end of rotor (2) that has a taper. 2. Make sure the side of bearing (4) that has a shield, is in a down position. Install the bearing in the plate with tool (A) and a press. 3. Install five vanes (5) in the rotor. 4. Install four retainers (9) in cylinder (8).5. Install dowel (10) in the plate and install the cylinder on the dowel and rotor. Make sure the dowel is installed in two holes (6) in either end of the cylinder. Two holes (7) in the cylinder must be in alignment with two left holes (11) in the plate. Two right holes (12) are not used for this model of air starter. 6. Install spacer (15) on the rotor.7. Install plate (13) on the cylinder. Make sure hole (14) in the plate is in alignment with the dowel. 8. Make sure the side of bearing (16) that has a shield is in a down position. Install the bearing in the plate and install the lock on the rotor.9. Install the nut with its large chamfer in a down position. Tighten the nut with tool (B) and bend the lock into one of the grooves of the nut to hold the nut in position. 10. Make a record of the four holes (20) and dowel hole (18) in housing (19). Dowel hole (17) is not used on this model of air starter. 11. Four retainers (9) in the cylinder must be in alignment with four holes (20) in the housing. Also, dowel (10) must be in alignment with hole (18) in the housing. Install rotor and cylinder assembly (21) in the housing. 12. Install washer (23) on the plate bearing.13. Install gasket (24) on the plate and install cover assembly (22) on the housing. Install the bolts that hold the cover assembly in position. Turn the rotor as the bolts are tightened to make sure the rotor will turn