OEM 2004 Toyota RAV4 Starter Motor

2004 Toyota RAV4 Starter Motor Parts Q&A

• Q: How to service and repair the starter motor on 2004 Toyota RAV4?

  A: Start the starter motor service by removing the dust protector followed by disconnection of the lead wire from the magnetic switch terminal upon nut removal with 5.9 N.m (60 kg.cm, 52 in.lb) torque setting. Service and repair of the starter motor starts with removing the two through bolts at identical torque values until you can pull out the field frame and armature while positioning the field frame protrusion into the magnetic switch indentation before assembly. The reassembly process requires a new O-ring for the field frame after its removal. The procedure calls for removing the starter housing and clutch assembly through nut unscrewing at 5.9 N.m (60 kg.cm, 52 in.lb) before retrieving all elements including starter housing, clutch assembly (1), return spring (2), idler gear (3), and bearing from the magnetic switch. When removing the steel ball inside the clutch shaft hole you should use a magnetic finger tool. The field frame bushing disassembly begins with removing two 1.5 N.m (15 kg.cm, 13 in.lb) screws and end cover before removing the O-ring and then disconnecting the four brushes from the brush holder under spring tension maintenance. Maintain bridging of the positive (+) lead wires when reinstalling the controls. High-temperature grease must be applied to bearings, springs, steel ball and gears before reversing the assembly steps. The procedure for clutch assembly replacement requires users to place a brass bar in a vise and then install the starter housing and clutch assembly followed by pinion gear downward force and stop collar tapping with a plastic-faced hammer to remove the snap ring and finally extract the stop collar and pinion along with compression spring. Construct the starter housing by fitting its components in the correct order: starter clutch first, then compression spring and clutch shaft, followed by spring retainer, pinion gear and stop collar while carefully installing the snap ring. Use SST 09286-46011 to detach the front bearing while SST 09820-00030 will press in the new bearing with attention to direction orientation. Execute the same method for the replacement of the rear bearing. Replacing magnetic switch terminal kit parts begins with removing three bolts and end cover, gasket, and plunger followed by measuring the contact plate depth that exceeds 0.9 mm (0.035 in.) to determine replacement. Use SST 09810-38140 to loosen the terminal nuts, extract necessary parts from terminal C and terminal 30, install new components with proper orientation of terminal insulators and wave washers installed. Applying 981 N pressure through a wooden block holding the contact plate allows users to achieve proper torque levels by tightening the nuts with SST 09810-38140 to 17 N.m. Over-tightening needs strict avoidance to protect the insulator from damage. Dry the contact surfaces with a shop rag while cleaning them before placing the plunger and new gasket inside and fastening the end cover using bolts that need tightening at 2.5 N.m torque (26 kg.cm, 23 in.lb).