OEM 2004 Toyota Sequoia Starter Motor

2004 Toyota Sequoia Parts Questions & Experts Answers

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

  A: One should begin the repair process of a starter motor by disassembling it. After unscrewing the nut and disconnecting the lead wire from the magnetic switch terminal with 5.9 N.m (60 kgf.cm, 52 in.lbf) torque and removing 2 through bolts with 9.3 N.m (95 kgf.cm, 82 in.lbf) torque the field frame together with the armature can be removed from the magnetic switch assembly by aligning field frame protrusions with magnetic switch grooves for assembly. The procedure for field frame O-ring removal requires discarding the existing O-ring and replacing it with a new one before reassembly. Two screws need to be removed according to the torque standard of 9.3 N.m (95 kgf.cm, 82 in.lbf) to take out the starter housing, clutch assembly, and gear. The technician should detach the starter housing from the remaining components including return spring, idler gear, bearing, and starter clutch assembly. Applying grease to the return spring is necessary before inserting it into the clutch shaft hole. A magnetic finger should be used to extract the steel ball from the clutch shaft hole while you apply grease to it before reinserting it back during reassembly. Replacing the brush holder requires dismounting the two screws with O-ring and end cover from field frame through 3.8 N.m (39 kgf.cm, 34 in.lbf) torque while adding a new O-ring during reinstallation. A screwdriver will allow you to hold the spring while you remove the brush holder from its position by disconnecting the brushes and you must avoid grounding the positive (+) lead wires. The process of changing the rear bearing requires using Special Service Tool: 09286-46011 both for extraction and bearing installation. Special Service Tool: 09286-46011 should be employed for front bearing removal after which you will need Special Service Tool: 09820-00031 to install a new bearing correctly. Disassemble the end cover with magnetic switch and 3 nuts while maintaining the 3 stud bolts tight then move the end cover, gasket, plunger and end cover sequentially. Use vernier calipers to check contact plate wear but replace it with a new one if the measurement exceeds 0.9 mm (0.035 in.). Users must apply a wooden block (20 X 33 X 40 mm or 0.79 X 1.30 X 1.57 in.) to the terminal kit parts before using Special Service Tool: 0981-38140 to loosen the terminal nuts with a hand press. Terminal C requires the removal of terminal nut and wave washer and both terminal insulators together with O-ring and terminal bolt and contact plate to perform repairs similarly for Terminal 30. Tighten the terminal nuts by performing a force of 981 N (100 kgf, 221 lbf) through new terminal 30 and C kit components while maintaining proper contact plate positioning to prevent it from tilting. The final procedure requires Special Service Tool: 09810-38140 to fasten the terminal nuts to 17 N.m (190 kgf.cm, 13 ft.lbf) torque. Next, clean both contact plate and plunger surfaces then replace the magnetic switch end cover with new gasket and end cover under a torque of 3.6 N.m (37 kgf.cm, 32 in.lbf). High-temperature grease serves to lubricate the bearing and gears when performing reassembly while following the opposite sequence of disassembly steps.