OEM 2002 Toyota Tundra Starter Motor

2002 Toyota Tundra Starter Motor Parts Q&A

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

  A: First service or repair the starter motor by taking out 2 dust protectors followed by removing the lead wire from the magnetic switch terminal after nut removal with 5.9 N.m (60 kgf.cm, 52 in.lbf) torque for 1.4 kW types but 9.3 N.m (95 kgf.cm, 82 in.lbf) for 2.0 kW types. Pull out the field frame and armature from the magnetic switch assembly while correctly aligning the field frame protrusion with the magnetic switch groove before taking out the O-ring from the field frame which requires a new O-ring during reassembly. Begin by taking out 2 bolts securing the 1.4 kW type with 5.9 N.m torque or 2 screws on the 2.0 kW type requesting 9.3 N.m torque then extract the starter housing and clutch assembly as well as gear and afterward extract the parts in this order: return spring, bearing and idler gear and starter clutch assembly. During assembly apply grease to the return spring. A magnetic finger tool should extract the steel ball from the clutch shaft hole while you should lubricate it before reinserting. To access the brush holder remove both O-ring mounting screws and field frame end cover along with their specified torque values (1.5 N.m for 1.4 kW type and 3.8 N.m for 2.0 kW type). Then take out the O-ring before disconnecting the 4 brushes while avoiding positive lead wire grounding. Copper coils should be separated from the magnetic core by undoing all steps in reverse sequence while applying high-temperature grease as a lubricant. The Special Service Tool: 09286-46011 enables users to replace and correctly install rear and front bearings using this tool. Regularly check and replace magnetic switch terminal kit parts by first opening the magnetic switch end cover to inspect the contact plate for wear (maximum worn amount: 0.9 mm) before any replacement takes place. With Special Service Tool: 09810-38140 users must untighten the terminal nuts before replacing the new Terminal C and Terminal 30 terminal kit parts while maintaining the correct insulator and wave washer installation orientation. Tighten the terminal nuts initially and apply full torque at 17 N.m (170 kgf.cm, 13 ft.lbf) on the contact plate using a wooden block set to 20 x 37 x 40 mm dimensions while applying 981 N (100 kgf, 221 lbf) press force. After cleaning the surfaces of contact plate and plunger, reinstall the magnetic switch end cover together with plunger, new gasket, end cover, and lead clamp with 3 bolts using a torque of 2.5 N.m for 1.4 kW type and 3.6 N.m the 2.0 kW type.