OEM 2003 Toyota Avalon Starter Motor

2003 Toyota Avalon Starter Motor Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2003 Toyota Avalon?

  A: Service and repair of the starter motor starts with dust protector removal followed by disconnecting the lead wire from the magnetic switch terminal after unthreading the nut which requires 5.9 N.m (60 kgf.cm, 52 in.lbf). The service begins with torque removal of the two through bolts then extraction of the field frame containing the armature. Adjust the position of field frame protrusion to match the magnetic switch indentation. Use a new O-ring to replace the one that you took out from the field frame. Unscrew the two screws at 5.9 N.m (60 kgf.cm, 52 in.lbf) to extract the starter housing together with the clutch assembly before moving on to remove the return spring, idler gear and bearing. A magnetic finger should be used to grasp the steel ball inside the clutch shaft hole. The field frame brush holder requires opening the two screws and end cover at 1.5 N.m (15 kgf.cm, 13 in.lbf) while removing the O-ring before detached brush leads from the brush holder without allowing the positive lead wires to contact ground. The reassembly process requires a start-to-finish sequence where high-temperature grease is used for lubricating the components including bearings, springs, steel ball and gears. A brass bar situated in a vise allows technicians to disconnect the starter housing along with its clutch assembly through pinion gear pushing, stop collar tapping with a plastic-faced hammer, snap ring extraction, and stop collar and pinion gear removal with the compression spring. Start by installing the compression spring along with the clutch shaft onto the starter clutch before securing the starter clutch to the starter housing through repeated steps to install the snap ring. The front bearing requires SST 09286-46011 to remove it while SST 09820-00031 will press in the new bearing with correct installation direction set. Apply this method to replace the bearing located in the back of the assembly. The replacement of magnetic switch terminal kit components begins with removing three bolts and end cover and gasket and plunger before measuring the contact plate 0.9 mm (0.035 in.) for longevity determination. Install the new terminal 30 kit components through SST 09810-38140 by following correct insulator and washer alignment before tightening with 17 N.m (173 kgf.cm, 12 ft.lbf) force. The terminal nuts can be tightened using SST 09810-38140 while using a wooden block to compress the contact plate using 981 Newtons force equivalent to 100 kgf (221 lbf) distributed over an 17 Newton meter range (173 kgf.cm, 12 ft.lbf) but avoid excessive force applied. A dry shop rag should be used to clean contact surfaces before installing the plunger together with its new gasket and end cover through bolt tightening at 2.5 N.m (25 kgf.cm, 22 in.lbf).