OEM 2004 Toyota Echo Starter Motor

2004 Toyota Echo Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2004 Toyota Echo?

  A: To service and repair the starter motor, begin by disassembling the components: remove the magnetic switch by disconnecting the lead wire and unscrewing the two nuts, then lift the front part to release the plunger hook from the drive lever; next, remove the field frame and armature by unscrewing the two through bolts and pulling them out together, followed by removing the O-ring from the field frame; then, take off the brush holder by unscrewing the two screws and end cover, removing the O-ring, and disconnecting the brush holder and four brushes; proceed to remove the armature from the field frame; take out the drive lever and starter clutch with shock absorber from the starter housing; remove the planetary gears by taking off the plate, three planetary gears, and plate washer; for the starter clutch, tap the stop collar towards it, pry off the snap ring, and remove both the stop collar and starter clutch from the planetary carrier shaft; then, remove the planetary carrier shaft and internal gear by using snap ring pliers to take off the snap ring and plate washer, followed by removing the planetary carrier shaft and plate washer, and finally, align the hollow of the internal gear with the protrusion inside the shock absorber to remove it. To replace the brushes start by trimming the brush lead wire followed by shaving the welded mark to specific measurements of 5.0 mm x 1.6 mm (0.197 in. x 0.063 in.) before soldering the supply brush plate over the terminal lead wire and shaving it to lengths of 7.0 mm x 3.3 mm (0.276 in. x 0.130 in.). During soldering avoid letting any material enter the field area. Replace the center bearing with Special Service Tool: 09221-25026 (09221-00090) and a press. For reassembly, lubricate bearings and sliding parts with high temperature-resistant grease, install the internal gear and planetary carrier shaft by applying grease and aligning the hollow of the internal gear with the shock absorber, then insert and turn it to interlock; apply turbine oil to the center bearing and grease to the plate washer before installing it to the planetary carrier shaft; install the starter clutch by greasing the bushing and spline, placing it on the shaft, and installing the snap ring; install the planetary gears by greasing them and the flange pin parts, then installing the plate washer and three gears; install the drive lever and starter clutch with shock absorber by greasing the pivot part, aligning the protrusion with the cutout, and installing them; place the armature into the field frame; install the brush holder by positioning it on the armature, holding the brush spring back to connect the brushes, installing a new O-ring, applying turbine oil to the bearing, and securing the end cover with two screws at a torque of 1.5 N.m (15 kgf.cm, 13 in.lbf); install the field frame and armature assembly with a new O-ring, aligning the cutout with the shock absorber, and securing with two through bolts at a torque of 5.9 N.m (60 kgf.cm, 52 in.lbf); finally, install the magnetic switch by hanging the plunger to the drive lever, securing it with two nuts at a torque of 8.3 N.m (85 kgf.cm, 73 in.lbf), and connecting the lead wire to the terminal with a nut at a torque of 9.8 N.m (100 kgf.cm, 87 in.lbf).