OEM 2003 Toyota Land Cruiser Starter Motor

2003 Toyota Land Cruiser Parts Questions & Experts Answers

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

  A: The starter motor service process begins with 2 dust protector removal followed by lead wire disconnect from the magnetic switch terminal using a nut with 5.9 N.m (60 kgf.cm, 52 in.lbf) torque setting. First unscrew the 2 through bolts to 9.3 N.m (95 kgf.cm, 82 in.lbf) before pulling out the field frame with armature through the magnetic switch assembly while setting the field frame protrusion into the magnetic switch groove. A new O-ring needs to be utilized when putting the field frame together after removing its original O-ring. Remove the starter housing with clutch assembly and gear by loosening two screws whose torque needs to reach 9.3 N.m (95 kgf.cm, 82 in.lbf). Afterward extract all items comprising the starter housing and return spring and idler gear and bearing and starter clutch assembly and coat the return spring with grease before inserting it into the clutch shaft hole. The steel ball can be taken out of the clutch shaft hole with a magnetic utility while applying fresh grease to the component for reinstallation. Use new O-rings when reinstalling the brush holder by unscrewing the 2 screws with O-ring and end cover from the field frame with a torque of 3.8 N.m (39 kgf.cm, 34 in.lbf). The spring must be held in place by a screwdriver when disconnecting the brush holder's 4 brushes. Additionally, check for any ground connections on the positive (+) lead wires. The bearing along with gears should be reinstalled in reverse sequence while applying high-temperature grease for lubrication. The process of bearing replacement includes using Special Service Tool: 09286-46011 both for removing and pressing a new rear bearing while Special Service Tool: 09820-00031 is required for the front bearing. The magnetic switch end cover's removal requires three bolts and the gasket and plunger to be taken out so inspection of the contact plate for wear can be performed while checking for wear depth below 0.9 mm (0.035 in.). Caretakers should use Special Service Tool: 09810-38140 to loosen terminal nuts before removing Terminal C and Terminal 30 parts from the terminal kit. Temporary installation of the parts with Special Service Tool: 09810-38140 requires following the correct installation order. Apply a press force of 981 N (100 kgf, 221 lbf) on the contact plate through a wooden block of size 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 inches) before using Special Service Tool: 09810-38140 to tighten the terminal nuts to 17 N.m (170 kgf.cm, 13 ft.lbf) without exceeding the limit. Place the clean plunger inside the magnetic switch end cover before installing a new gasket followed by end cover and then lead clamp with 3 bolts secured at 3.6 N.m of torque (37 kgf.cm, 32 in.lbf).