OEM 2003 Toyota Sequoia Starter Motor

2003 Toyota Sequoia Parts Questions & Experts Answers

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

  A: Beginning the starter motor service requires first removing the nut and lead wire from the magnetic switch terminal using 5.9 N.m (60 kgf.cm, 52 in.lbf) torque followed by loosening the 2 through bolts with 9.3 N.m (95 kgf.cm, 82 in.lbf) torque so you can extract the field frame with armature from the magnetic switch assembly but make sure to place the field frame protrusion inside the magnetic switch groove when reassembling. You must take out the O-ring from the field frame for installation of a fresh O-ring before assembly. Remove the starter housing and clutch assembly and gear by first removing two screws with a torque strength of 9.3 N.m (95 kgf.cm, 82 in.lbf). Then separate the starter housing along with the return spring, idler gear, bearing, and starter clutch assembly. Before putting the return spring back into the clutch shaft hole, apply grease to it. A magnetic finger will extract the steel ball from the clutch shaft hole during the reassembly process by first applying grease to it before insertion. First remove the 2 screws with O-ring and end cover from the field frame by applying 3.8 N.m (39 kgf.cm, 34 in.lbf) torque after taking off the O-ring to disconnect the 4 brushes from the brush holder without grounding positive (+) lead wires. Reassembly occurs in the opposite sequence of disassembly and requires application of high-temperature grease on both bearing and gears. Special Service Tool: 09286-46011 and press must be used to remove the rear bearing while specifying the correct direction for insertion with this tool and Special Service Tool: 09820-00031 along with a press for the front bearing replacement. The replacement procedure begins by removing the magnetic switch end cover and three nuts followed by end cover, gasket, and plunger without disturbing the stud bolts. After this, check the contact plate wear and order a replacement when it exceeds 0.9 mm (0.035 in.) depth. Practical tools include both a hand press and Special Service Tool: 0981-38140 to separate the terminal nuts from the wooden block (20 x 33 x 40 mm or 0.79 x 1.30 x 1.57 in.). New terminal kits should be mounted at terminal C and terminal 30 with hand press force of 981 N (100 kgf, 221 lbf) while measuring gauge pressure from the hand press ram diameter. The final sequence involves utilizing Special Service Tool: 09810-38140 to achieve a nut torque setting of 17 N.m (170 kgf.cm, 13 ft.lbf) and afterward cleaning the contact surfaces before reinstalling the magnetic switch end cover with its plunger, new gasket, and end cover secured by 3 nuts at 3.6 N.m (37 kgf.cm, 32 in.lbf).