Instruction Manual

NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
© 2012 Remy International, Inc. All rights reserved 1
Technical support: USA 800 272 0222, Mexico 01 800 000 7378, Brazil 0800 703 3526, South America 55 11 2106 6510 or visit
delcoremy.com
INSTALLING 44MT™ GEAR REDUCTION HEAVY DUTY STARTING MOTORS
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. A professional installation specialist should handle
mechanical repairs that are beyond your technical capabilities.
DANGER!!! ALWAYS DISCONNECT BATTERY GROUND BEFORE REMOVING OR REPLACING CABLES AT THE STARTER.
FAILURE TO DISCONNECT THE BATTERY GROUND CABLE CAN LEAD TO SERIOUS INJURY.
NOTICE! The Delco Remy
Ⓡ
gear reduction starters can replace starters with or without an attached magnetic switch (relay) and over
crank protection (OCP). All 44MT™ starters have a magnetic switch (relay) internal to the solenoid and the OCP is pre-wired.
FOLLOW ENGINE AND/OR VEHICLE MANUFACTURER'S INSTRUCTIONS CAREFULLY WHEN REMOVING AND INSTALLING
THE STARTERS.
INSTALLATION AND MOUNTING
 If any shims and/or spacer washers were used with the old starter, between the starter and flywheel housings, they must be
reinstalled in exactly the same location with this starter.
 Starter cable lengths must allow for normal engine movement in all operating ranges.
 Solenoid position must be 10 degrees above horizontal to prevent moisture entry into the solenoid. See graphic, page 2.
44MT STARTERS HAVE ROTATABLE POSITIONING DRIVE HOUSINGS (Figure 1, page 2)
 This starter is provided with multiple solenoid switch positions (SWP), so several models may be serviced with a few.
 The housing may need to be rotated to insure the solenoid is at least 15 degrees above the center line. See graphic, page 2.
 Reposition the solenoid by removing six (6) TORX drive housing bolts and rotating housing to a different set of holes.
 Reinstall the six (6) drive housing bolts and torque bolts to 17.6 - 29.8 Nm (13 - 22 lb ft).
MOUNTING FLANGE HOLES AND MOUNTING BOLTS (Figures 1, page 2)
 These starters have two (2) possible mounting flange diameter holes sizes [16.75 mm (5/8”) & 13.5 mm (1/2”)].
NOTICE! Starters with 16.75 mm (5/8”) diameter flange mounting holes can also be mounted with 13.5 mm (1/2”)
mounting bolts. Hex Head Cap Screws (Grade 5) should always be used. If the hex head size is too small, use a
hardened washer or special 12-point head cap screw (Grade 5).
 Do not use any lock washers, star washers or soft washers with the starter mounting bolts.
ELECTRICAL CONNECTIONS (Figure 2, page 2)
 Identify and tag all leads when removing old starter so they can be properly connected on the new starter.
 Clean or wire brush all terminals so that bare metal is exposed for good electrical connections.
NOTE! If replacing a starter with over crank protection (OCP), the vehicle’s OCP mating connector is not used. However, it is
necessary to close the vehicle ground circuit for the vehicle to operate.
 Install the grounding plug (P/N 10528396), included in the shipping carton, into vehicle’s OCP connector to close the circuit.
 Secure the OCP connector and grounding plug to prevent chafing and separation due to vibration.
 Verify main cranking circuit voltage drop is less than 0.5 volts at 500 amps [See TMC RP 129A]. If voltage drop exceeds this
recommendation, appropriate corrections should be made prior to installing the 44MT starter.
THESE INSULATED STARTERS CAN REPLACE GROUNDED STARTERS (Figures 1 & 2, page 2)
Insulated starters have an insulated terminal on the commutator end. An insulated starter must have a cable connecting this terminal to
a battery ground (-) connection for the starter to function. This grounding cable between the starter and battery should be a copper
cable the same size as the positive (+) battery cable being used.
RING GEAR TEETH CONDITION
If the ring gear is damaged, it must be replaced to avoid a potential premature failure
and risk rejection of a warranty claim.
 Inspect ring gear for being fractured, bent, chipped, excessive wear, milled, etc.
 Bar over ring gear and inspect 360 degrees for damage.
BATTERY COLD CRANKING AMPERES (CCA)
Excessive available CCA can damage starters. CCA rating is the current a battery can
supply at “0” degree F (-18C) [See TMC RP 109A]. Following is the maximum
battery CCA recommendations for Delco Remy 44MT starters: 12 volt 3600 CCA
Reference: Service Bulletin 1B-216, 1M-153 24 volt 1800 CCA
INSTRUCTION SHEET
10530248
04OC13 Rev 3
44MT STARTER FEATURES:
 SOLENOID HAS AN INTERNAL MAGNETIC SWITCH (RELAY) THAT REDUCES WIRING CONNECTIONS
 BUILT IN OVER CRANK PROTECTION (OCP) IN ALL STARTERS ELIMINATES OCP WIRING HARNESS
 ROTATABLE NOSE HOUSING REDUCES SERVICE PART NUMBERS
 MOST POWERFUL 12 VOLT STARTER IN THE INDUSTRY: 8.5kW and 14% faster cranking speed than the industry standard
Bad - Replace OK - Normal Wear