OEM 2004 Toyota 4Runner Starter Motor

2004 Toyota 4Runner Starter Motor Parts Q&A

• Q: How to overhaul a 1.6 KW starter motor on 2004 Toyota 4Runner?

  A: The first step when replacing a 1.6 KW starter motor starts with the disconnection of the lead wire and unfastening the two screws holding the repair service starter kit onto the starter drive housing. The removal process also includes the return spring and plunger. The next step includes starter yoke assembly removal through the process of unscrewing two through bolts and pulling it out with the commutator end frame assembly. First loosen the connection between the commutator end frame assembly and starter yoke assembly while next removing the starter armature plate. Insert a screwdriver to remove the starter commutator end frame cover before applying snap ring pliers to eliminate the snap ring and plate washer allowing extraction of the starter armature assembly from the commutator end frame assembly. You should first extract the three planetary gears before removing the starter center bearing clutch sub-assembly together with the drive lever set pin. An ohmmeter should inspect starter armature assembly commutator segments for continuity. A broken connection would show the armature needs replacement. Begin by cleaning all burnt and dirty surfaces on the commutator using sandpaper (No.400) or a lathe before measuring it with vernier calipers for length which must stay under 3.8 mm (0.150 in.). The brush holder measurement of the starter commutator end frame assembly requires replacement if it falls below 9.0 mm (0.354 in.) while the positive and negative brush holders need inspection for electrical connection continuity. The analysis of planetary gear and starter center bearing clutch teeth should be performed for wearing components which require replacement. The clutch pinion gear must freely rotate in clockwise direction while locking in the counterclockwise direction; a new center bearing clutch sub-assembly must be installed if this condition is not met. Measure the plunger speed of a repair service starter kit while testing pull-in and hold-in coils with an ohmmeter because any open circuit prompts replacement of the kit. Start by fixing the drive lever set pin to the center bearing clutch and then put both components into the starter drive housing. Begin the installation process by applying grease to both the planetary parts and pin structures then add the starter armature assembly with attention paid to the plate washer as well as to the armature shaft. First install the plate washer then place the new snap ring before verifying the snap ring length remains below 5.0 mm (0.197 in.). After fitting the starter commutator end frame cover you must place the starter armature plate with its key inside the starter yoke and then install the starter commutator end frame assembly. Secure the starter yoke assembly to its corresponding starter drive housing with two through bolts that reach a torque level of 6.0 Nm (61 kgf.cm, 53 in.lbf). Follow by applying grease on the plunger and hook components of the repair service starter kit. After that hook the plunger to drive lever while installing plunger and return spring until the kit has two screws tightened to 7.5 Nm (76 kgf.cm, 66 in.lbf). Then connect lead wire to terminal with a nut torqued to 10 Nm (102 kgf.cm, 7.4 ft.lbf).