OEM 2004 Toyota Solara Starter Motor

2004 Toyota Solara Starter Motor Parts Q&A

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

  A: The repair process starts with magnetic switch assembly removal through lead wire disconnect and two mounting screw removal from the starter drive housing after which the switch and return spring can be extracted along with the plunger. First remove the starter field frame assembly by unfastening two through-bolts to pull out the field frame with the commutator end frame before separating these components. You need to extract the starter armature plate from its position in the field frame using a screwdriver to separate the starter commutator end frame cover. To remove the starter armature assembly use snap ring pliers to uninstall the snap ring and plate washer after taking out the armature from the commutator end frame. Take away the three planetary gears which exist in the starter drive housing. Verify the magnetic switch assembly by observing the plunger quick return followed by pull-in coil resistance testing at terminals 50 and C (up to 1 ohm) and hold-in coil resistance testing at terminal 50 to the switch body (up to 2 ohm); replace the assembly when any measurement falls outside of specifications. Inspect the starter armature assembly by measuring the resistance between the commutator segments (standard: below 1 ohm) and checking for grounding by measuring the resistance between the commutator and armature coil core (standard: 10 k ohm or higher); also check for contamination and burns on the commutator surface, correcting any issues with sandpaper (No. 400) or a lathe, and measure the commutator's length (standard length: 3.1 to 3.8 mm); replace the starter armature if the length exceeds the maximum. The starter commutator end frame assembly needs brush length measurement within its specified range (4.0 to 9.0 mm) as well as brush insulation testing through positive and negative brush resistance checks (minimum standard: 10 k ohm). An assembly replacement or repair should be done when these requirements are not met. Check the clutch pinion gear free movement by rotating it counterclockwise and ensure its locking function when rotating clockwise; replace the clutch if defects are found. The assembly process requires the application of grease on planetary gears and pin elements of the planetary shaft followed by the placement of three planetary gears. A dry plate washer with an armature shaft receives grease as maintenance technicians install it to the commutator end frame using snap ring pliers to put on a new snap ring of less than 5.0 mm length. The technicians will install the commutator end frame cover before placing the armature inside the field frame by lining up the keyway with the field frame's key. Secure the starter commutator end frame assembly by firstly positioning the rubber into the field frame cutout then adding the starter field frame assembly making sure the protrusion fits into the starter drive housing cutout after using two through bolts at a torque of 6.0 Nm. Install the magnetic switch assembly by first greasing the plunger and hook then hanging the plunger hook onto the drive lever before putting in the plunger and return spring and fastening the magnetic switch with two screws tightened to 7.5 Nm and connecting the lead wire onto the magnetic switch using a nut tightened to 10 Nm.