Pinion Gap Adjustment

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the field coil wire from the M-terminal of the magnetic switch.
Connect a 12-volt battery between the S-terminal and M-terminal.
CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
Set the switch to "ON," and the pinion will move out.

Fig 1: Connecting Battery Between The S-Terminal And M-Terminal (2.4L Engine)
Courtesy of DAIMLERCHRYSLER CORPORATION

Fig 2: Connecting Battery Between The S-Terminal And M-Terminal (3.0L Engine)
Courtesy of DAIMLERCHRYSLER CORPORATION
Check the pinion-to-stopper clearance (pinion gap) with a feeler gauge.
Standard value: 0.5 - 2.0 mm (0.02 - 0.07 inch)

Fig 3: Identifying Pinion-To-Stopper Clearance
Courtesy of DAIMLERCHRYSLER CORPORATION
If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the magnetic switch and front bracket.

Fig 4: Removing Gasket Between The Magnetic Switch And Front Bracket
Courtesy of DAIMLERCHRYSLER CORPORATION