OEM 2004 Toyota Tundra Starter Motor

2004 Toyota Tundra Parts Questions & Experts Answers

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

  A: First service the starter motor by disassembling it through field frame and armature removal after disconnecting the lead wire from the magnetic switch terminal and removing two through bolts at 5.9 N.m (60 kgf.cm, 52 in.lbf) for 1.2 kW and 1.4 kW types and 9.3 N.m (95 kgf.cm, 82 in.lbf) for the 1.8 kW type. The field frame and armature should be pulled out from the magnetic switch assembly before removing the O-ring and adding a new one when rebuilding the system. The next step requires unscrewing two screws from the starter housing and clutch assembly and gear before taking out the components from the magnetic switch assembly with identical torque settings. A magnetic finger should be used to extract the steel ball from the clutch shaft hole before removing the brush holder by unscrewing its two screws while observing torque limits. Remove the brush holder by unscrewing its two screws after disconnecting its brushes. The rear bearing installation should start using Special Service Tool: 09286-46011 to uninstall and press in a new bearing followed by the front bearing installation using the same tool and Special Service Tool: 09820-00031. Evaluate the magnetic switch end cover to check the contact plate depth against 0.9 mm (0.035 inches) and replace this part if the measurement exceeds this value. Make use of Special Service Tool: 09810-38140 to loosen the terminal nuts before replacing essential components at terminal C and terminal 30 with proper installation. The new terminal components should be installed while keeping them tight for a short period using a wooden block press against the contact plate before screwing the nuts down to 17 N.m using 170 kgf.cm or 13 ft.lbf. Clean the surfaces then return the plunger along with a new gasket and end cover before fastening the lead clamp at specified bolt torque points. High-temperature grease must be used for all bearings and gears and return spring and steel ball as you reassemble the starter motor in the reverse order of disassembly.