OEM 2004 Scion xA Starter Motor

2004 Scion xA Parts Questions & Experts Answers

• Q: How to overhaul the starter motor on 2004 Scion xA?

  A: The starter motor repair starts with lead wire removal followed by unscrewing the two bolts holding the repair service starter kit in place until kit extraction and its components of return spring and plunger. The starter commutator end frame cover must be removed using a screwdriver. The starter yoke assembly and commutator end frame assembly need to be extracted together by pulling after removing their two through bolts. After that separate the starter yoke assembly from the commutator end frame assembly. Start by using snap ring pliers to remove the snap ring with plate washer before you accomplish the extraction of the starter armature assembly from the commutator end frame assembly. First remove the starter armature plate from the starter yoke then proceed with removing the three planet gears. Detach the starter center bearing clutch along with its drive lever set pin from the starter drive housing before removing the drive lever set pin from the starter center bearing clutch sub-assembly. An ohmmeter test must be conducted on the starter armature assembly to check if the commutator segments show any continuity; if no continuity is detected the armature needs replacement. A continuity test should be carried out between the commutator and armature coil core. If the test results in continuity then the armature needs replacement. The cleaning process for the commutator surface requires 400 grit sandpaper or a lathe machine to remove burn marks or dirt and the commutator length needs measurement using vernier calipers for replacement when it measures beyond 3.8 mm (0.150 in.). Check the brush length for the starter assembly because it needs replacement if the length falls below 9.0 mm (0.354 inches). Also test brush continuity between positive and negative contacts and repair or replace the starter assembly if any continuity exists. A thorough inspection of the starter clutch components along with planetary and internal gears must occur with wear and damage assessment followed by replacement of faulty parts. The clutch needs a proper clockwise rotation with counterclockwise locking ability that demands a new center bearing clutch sub-assembly in case of failure. Quick plunger operation and open-circuit testing of pull-in and holding coils should be performed to detect failures that require starter assembly replacement. One must install the starter center bearing clutch sub-assembly by first attaching the drive lever set pin before reinserting it into the starter drive housing. A thin coat of grease should be applied to the planet gears and pin parts of the planetary shaft before the three planet gears are installed. The starter armature plate must be slid inside the starter yoke assembly, followed by a correct alignment step before greasing the washer plate and armature shaft for insertion into the starter commutator end frame assembly. To mount the plate washer along with the snap ring use snap ring pliers but check the snap ring length because any measurement above 5.0 mm (0.197 in.) requires a replacement. Place the starter commutator end frame cover back in its position followed by proper alignment of the starter yoke assembly to the starter commutator end frame. Secure the two through bolts that link the starter housing keyway with the starter yoke assembly key through a torque setting of 6.0 Nm (61 kgf.cm, 53 in.lbf). Finish the process by greasing the repair service starter kit plunger and hook and mounting the plunger hook onto the drive lever before installing the plunger and return spring then securing the kit with two screws that require 7.5 Nm (76 kgf.cm, 66 in.lbf) torque before joining the lead wire to the terminal and tightening the nut to 10 Nm (102 kgf.cm, 7.4 ft.lbf).