OEM 2002 Toyota RAV4 Starter Motor

2002 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2002 Toyota RAV4?

  A: Begin servicing or repairing the starter motor with dust protector removal before you disconnect the lead wire from the magnetic switch terminal through removing the appropriate nut while maintaining 5.9 N.m (60 kg.cm, 52 in.lb) torque. The field frame containing the armature must be extracted when both through bolts are removed using proper torque then reposition the field frame protrusion against the magnetic switch indentation for reinstallation. The field frame O-ring must be removed before installation of a new replacement O-ring during reassembly. Reverse the order by unboltening two screws on the starter housing and clutch assembly with 5.9 N.m (60 kg.cm, 52 in.lb) torque then extract the starter housing, clutch assembly (1), return spring (2), idler gear (3) and bearing from the magnetic switch. The steel ball needs to be pulled out using a magnetic finger from inside the clutch shaft hole. Disassemble the brush holder by using a screwdriver to remove its spring back position and detach the four brushes from their holder after pulling out the end cover and two screws and the O-ring from the field frame with a torque of 1.5 N.m (15 kg.cm, 13 in.lb). It is essential to avoid grounding the positive lead wires when reconnecting the electrical components. The assembly process occurs in backward order while adding high-temperature grease to bearings, springs, steel ball and gears. The replacement process for clutch assembly starts by installing a brass bar in a vise for disassembling the starter housing and clutch assembly to complete removal. The pinion gear needs pushing downwards while using a plastic-faced hammer on the stop collar to tap it down. Then remove the snap ring and stop collar and pinion, compression spring. First push down the starter housing through which you will remove the spring retainer and clutch shaft as well as compression spring and starter clutch. Reassembly begins by first putting the starter clutch followed by compression spring then clutch shaft inside the starter housing. Then continue the stop collar and snap ring mounting process two more times while maintaining precise alignment. Install new bearings by using SST 09820-00030 with SST 09286-46011 tool which includes specific instructions for proper bearing insertion direction. Install the same steps to the rear bearing. Replace the magnetic switch terminal kit parts by first removing the three bolts followed by end cover and gasket and plunger. Inspect the contact plate depth wear then replace it if it exceeds 0.9 mm (0.035 in.). Clean both terminal C and terminal 30 by using SST 09810-38140 to unscrew their terminal nuts before removing old parts while properly orienting new replacement components for correct installation and tightening the terminal nuts. The technician will press down the contact plate by applying 981 N of force (100 kg, 221 lb) through a hand press while using a wooden block with dimensions of 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.). Afterward, the technician will fasten the terminal nuts to a torque of 17 N.m (173 kg.cm, 13 ft.lb) with SST 09810-38140 before cleaning all contact surfaces and reinstalling the plunger, new gasket, and end cover through three bolts set to a torque 2.5 N.m (26 kg.cm, 23 in.lb).