OEM 2002 Toyota Tacoma Starter Motor

2002 Toyota Tacoma Parts Questions & Experts Answers

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

  A: To service and repair the starter motor, begin by disassembling it: remove the nut and disconnect the lead wire from the magnetic switch terminal with a torque of 5.9 N.m (60 kgf.cm, 52 in.lbf), then take out the 2 through bolts with respective torques of 5.9 N.m (60 kgf.cm, 52 in.lbf) for 1.4 kW and 9.3 N.m (93 kgf.cm, 82 in.lbf) for 2.0 kW, and pull out the field frame with the armature from the magnetic switch assembly, ensuring to align the protrusion of the field frame with the cutout of the magnetic switch during reassembly. You should change the O-ring before installing a new one during assembly. Unscrew the 2 screws from the starter housing, clutch assembly, and gear by using the same torque values followed by starter housing and return spring and clutch assembly and idler gear and bearing removal from the magnetic switch assembly using tools. Ask for a magnetic finger tool to extract the steel ball from the clutch shaft opening and afterward remove the field frame end cover screws with 1.5 N.m (15 kgf.cm, 13 in.lbf) torque for 1.4 kW units and 3.8 N.m (38 kgf.cm, 34 in.lbf) torque for 2.0 kW units before separating the brushes from the brush holder by setting back the spring with a screwdriver. The assembly process should resume starting from the opposite direction with high-temperature grease used to lubricate the bearings, gears, return spring and steel ball. The front bearing replacement requires Special Service Tool: 09286-46011 to press out the front bearing while the press-in operation of the new one uses Special Service Tool: 09820-00031 before repeating the procedure for the rear bearing. Inspection of magnetic switch terminal components includes removing the 3 bolts and end cover then checking the plunger depth to determine replacement if it exceeds 0.9 mm (0.035 in.) measurement. Use Special Service Tool: 09810-38140 to loose Terminal C and Terminal 30 nuts before removing components. Then install new terminal parts into place but ensure the correct orientation of terminal insulators. Use a wooden block pressure the contact plate to the same force of 981 N (100 kgf, 221 lbf) before applying a torque of 17 N.m (173 kgf.cm, 13 ft.lbf) while being careful to avoid insulator damage. Clean and install the plunger and new gasket and end cover and lead clamp while applying torques of 2.5 N.m for 1.4 kW and 3.6 N.m for 2.0 kW.