GROUP

HyunaRI I

NUMBER
13-EE-001

ENGINE

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ELECTRICAL
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Technical Service Bulletin

DATE
JANUARY 2013

MODEL(S)
Sonata (NF/YF)
Santa Fe (CM/AN)

STARTER MOTOR LEVER REPLACEMENT

SUBJECT:

NOTE: This bulletin is revised to add 2012-2013MY. A bench test has been added to the Initial Starter
Inspection procedure to confirm the starter incident condition. Be sure to install the lever stop as
described in step-14. A review of warranty return parts show the lever stop missing on some incident
starters replaced subsequent to this repair attempt.

Description:
• This bulletin provides the repair procedure for replacing the starter motor lever in some
2009-2013MY 2.4L Sonata , and 2010-2013MY 2.4L Santa Fe.
• The symptom for this incident is a No Start condition.
• The starter motor spins, but the starter does not crank the engine .
• When the starter is bench tested, the pinion gear does not travel out or retract fully.
• When this condition is confirmed , starter lever should be replaced per procedure of this bulletin .
NOTE: Starters replaced as an assembly will be subject to WTC Part Return Request. Claim adjustment may
occur if a broken lever is present but the repair procedure was not properly followed . If during disassembly for
this bulletin, a condition is confirmed requiring the starter assembly to be replaced (other than the lever) ,
reassemble the starter completely (hand tight screws are OK). Describe clearly on the Repair Order why the
starter had to be replaced .
Broken lever found at disassembly:

Applicable Vehicles:
• 2010-2013MY SANTA FE (CM/AN) 2.4L
• 2009 -2013MY SONATA (NF/YF) 2.4L
Parts Information:

Warranty Information:
Model

Op Code

Operation

YF/NF,
CM/AN

36131FOO

Starter Lever
Replacement

Op Time Causal Part# Nature Code Cause Code
0.8

36100-2G100

N59

C06

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors , Technicians, Body Shop Manager, Fleet Repair

ST ARTER MOTOR LEVER REPLACEMENT

SUBJECT:

Tools Required:
•
•
•
•
•

Torque Wrench
?mm and 13mm Sockets
TORX T20 Screwdriver
Permanent Marker Pen (to make alignment marks on the starter parts)
Remote Starter Switch

Initial Starter Inspection:
i.

Starter Removal :
(1) Note customer radio presets so as to
program them back later.
(2) Disconnect the battery negative cable .
(3) Disconnect the starter cable (A) from the
B-terminal (B) on the solenoid (C).
(4) Disconnect the connector (D) from
the S-terminal (E) .
(5) Remove the 2 bolts holding the starter,
and then remove the starter.

ii .

D

Perform Diagnostic Bench Test:
Follow~

the below Warnings and Notes:

B WARNING
•
•
•

•

During this operation the starter will activate, and the body of the starter must
be secured from moving (ex: placing in a vise).
Keep hands/fingers/ loose clothing away from the pinion or personal injury
may result.
To avoid electrical shock, first connect booster cables between the 12V
battery and the solenoid 8-terminal (high current), without touching the
solenoid S-terminal.
The starter is then safely activated by contacting 12V to the solenoid $terminal (low current) such as by a remote starter switch tool.

TSB # : 13-EE-001

Page 2 of 11

STARTER MOTOR LEVER REPLACEMENT

SUBJECT:

*NOTE
•
•

Do not activate contactor (A) more than 5 seconds to avoid damage of the starter coil.
When contactor (A) is activated , the pinion must extend and the starter must rotate .

Perform this functional test per the illustrated setup below.
•

Confirm that the motor spins OK.

•

Confirm pinion gear operation :
o

If pinion gear fails to move out or retract fully, then perform the remainder of this
bulletin to repair a broken lever.

Rear view

)

S-Terminal

(-)

(+)

12V Battery or
Booster Box

*NOTE
•
•

This bulletin does not apply if the starter spins too slow or does not spin at all.
In this case perform normal warranty repair for a starter replacement.

TSB # : 13-EE-001

Page 3 of 11

ST ARTER MOTOR LEVER REPLACEMENT

SUBJECT:

Starter Disassembly and Inspection:

1.

Apply 2 pairs of alignment marks from front
bracket (A) to solenoid (8) , and front bracket
(A) to the yoke assembly (C) as shown .

c

*NOTE
Alignment marks are necessary to
assure proper function of the starter
after reassembly.
2.

Using a 13mm socket, remove each of the
following :
• Starter solenoid M terminal nut (E)
• Terminal wire (D).

3.

Using a TORX T20 screwdriver, remove the
following:
• 2 solenoid screws (C).
NOTE: Discard these 2 screws which
will be replaced by new screws from
the kit.
• Solenoid assembly (D) from starter.

B

E

*NOTE
•
•

4.

Do not clean grease from the
spring/plunger.
If the solenoid is dropped/damaged it
cannot be reused. Replace the
solenoid with part 36120-28110.

Using a ?mm socket, remove the through
bolts (F) that are holding the yoke assembly
to the front bracket.

TSB # : 13-EE-001

Page 4 of 11

SUBJECT:

STARTER MOTOR LEVER REPLACEMENT

5.

Slightly pull out the yoke assembly (C) from
the front bracket (A) to apply a new
alignment mark between front bracket (A) ,
reducer assembly (B) and yoke (C) .

6.

Remove the yoke assembly (C) with the
armature and end cap contents intact as an
assembly.

c

*NOTE
Do not remove components from the yoke
assembly (C)

7.

Remove lever stop (D) from the front
bracket.

8.

•

Remove reducer assembly (E) from front
bracket (A) .

•

Remove broken lever (C) from ORC (D).
(ORC= Over Running Clutch)

D

TSB # : 13-EE-001

E

Page 5 of 11

STARTER MOTOR LEVER REPLACEMENT

SUBJECT:

-

*NOTE

Component Inspection:
• ORC must rotate in one direction and lock in the opposite direction without any
rough spots.
• If the ORC is found to be faulty stop this procedure and perform normal warranty
repair for a starter replacement.

9.

Remove the lever (A) from plunger by pointing lever up and removing from pins (8).

B

Lever Replacement:

10.

Install the replacement lever (A) by aligning
slots with pins and moving lever at a right
angle (90 degrees) from to the plunger (B)
as shown .

*NOTE
After assembly, do not remove the lever
from the 90 degrees position.

TSB #: 13-EE-001

Page 6 of 11

STARTER MOTOR LEVER REPLACEMENT

SUBJECT:

11 .

Apply the grease (A) provided in the parts kit
onto the ORC (B) as shown.

B

12.

Install the plunger and lever assembly
onto the ORC assembly.

13.

Place the front bracket (A) on
a support and insert the ORC assembly (B) ,
be sure to align the marks that were placed
during step-6 of disassembly.

A

TSB #: 13-EE-001

B

Page 7 of 11

STARTER MOTOR LEVER REPLACEMENT

SUBJECT:

*NOTE
•
•

14.

Confirm correct alignment marks between the front bracket and ORC .
Correct assembly check : There should be no gaps between stopper (C) and front
bracket (A) .

Install lever stop (D)

*NOTE
The lever stop (F1) should be flush with
the front bracket (F2).

15.

Using a 7mm socket and torque wrench
install 2 through bolts (A) and (B) into yoke
assembly and bracket.
Tightening sequence:
1: Bolt (A) (torque = 8 to 9 Nm)
2: Bolt (B) (torque = 8 to 9 Nm)
3: Confirm bolt (A) torque (8 to 9 Nm)

TSB #: 13-EE-001

Page 8 of 11

SUBJECT:

STARTER MOTOR LEVER REPLACEMENT

*NOTE
Inspection for Correct Reassembly:
• Ensure the lever stop (C) remains in the position shown.
• Ensure that the plunger spring (D) is still in place.

16.

•

•

•

Be sure to assemble the yoke assembly to the front bracket according to the
marks placed during disassembl1' of Step-1 .

•

Verify that the 2 long bolts are in contact with the yoke assembly. If not,
disassemble and restart the installation o eration .

•

Check that the yoke assembly (E) is in contact with front bracket (F) . If not, go
back to Step-15 and check for proper alignment of reducer gear to the front
bracket.

Install solenoid (A) onto the starter
assembly (B) ensuring that the plunger
spring is still in place.
Using a TORX T20 screwdriver Install 2
new solenoid screws (C) and (D) from
the kit into solenoid and front bracket.

A

Tightening sequence:
1: Solenoid screw (C) (torque= 3.0-4.2Nm)
2: Solenoid screw (D) (torque= 3.0-4.2Nm)
3: Confirm screw (C) torque (3 .0-4.2 Nm)

TSB # : 13-EE-001

Page 9 of 11

ST ARTER MOTOR LEVER REPLACEMENT

SUBJECT:

*NOTE
Inspection for Correct Reassembly:
• Be sure to assemble the solenoid according to the marks placed during
disassembly in Step-1.
• Check that the 2 screws (C) and D are in contact with front bracket (E) .

•
•

Check that solenoid (A) is in contact with front bracket (E) . If not, disassemble
and restart the installation operation (Step-18).
Install M wire (A) onto solenoid M terminal (8) . Using a 13mm socket and torque
wrench , tighten M terminal nut (C) to 7.8-11 .8 Nm.

c

•

After applying torque , ensure that the nut (C) is in contact with the braid.

,-,

c

TSB #: 13-EE-001

Page 10 of 11

SUBJECT:

STARTER MOTOR LEVER REPLACEMENT

Starter Functional Test after reassembly:

17.

Perform starter bench test.
Refer to procedure detailed on page 3 and re-test starter to confirm successful repair. If any
abnormal noise is detected , recheck the steps of the assembly procedure to ensure proper
assembly.

Starter Installation:

18.

Install starter in reverse order of removal.

19.

Connect negative battery cable.

20.

Reprogram the customer radio presets.

TSB # : 13-EE-001

Page 11 of 11