OEM 2005 Toyota 4Runner Starter Motor

2005 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to service and repair the Starter Motor (1.6KW) on 2005 Toyota 4Runner?

  A: The Starter Motor (1.6KW) repair process starts by removing the nut and cutting the lead wire from the repair service starter kit and continuing with screw removal from the starter drive housing to extract the repair service starter kit together with return spring and plunger. First disconnect the starter yoke assembly together with the commutator end frame assembly by pulling out its two through bolts. You should pull off the starter armature plate from the starter yoke assembly and utilize a screwdriver to detach the starter commutator end frame cover. You need snap ring pliers to eliminate the snap ring alongside plate washer before you can separate the starter armature assembly from the commutator end frame assembly. The starter center bearing clutch sub-assembly can be removed after disassembling the starter drive housing into its component parts of starter center bearing clutch with drive lever set pin. Then detach the drive lever set pin from the starter center bearing clutch. Use an ohmmeter to check if the starter armature assembly shows no continuity between commutator segments when measuring with an ohmmeter; replace the armature if needed. A continuity check between the commutator and armature coil core should be done; if continuity is found then replace the armature. After cleaning the commutator surfaces with sandpaper No.400 or a lathe (3.8mm 0.150in.) must replace the armature. The starter commutator end frame assembly's brush holder length must be replaced if it measures less than 9.0 mm (0.354 inches) while any brush holder continuity should be repaired or the assembly replaced. The inspection of planetary gear teeth and starter center bearing clutch should check for damage while replacing broken planetary units or damaged clutches. A free rotating clutch pinion gear in clockwise direction coupled with clockwise mechanical locking requires replacement of the center bearing clutch sub-assembly. Check the plunger of the starter repair kit for proper restoration and obtain a new kit if the plunger does not return fast enough. Open circuit continuity tests should be done on the pull-in coil between terminals 50 and C making the kit replacement necessary when continuity is missing. The same evaluation should be done on the hold-in coil between terminal 50 and the switch body. Start by mounting the drive lever set pin onto the starter center bearing clutch before joining all components to the starter drive housing. Before installing the three planetary gears start by greasing both the planetary gears and their attached pins located on the planetary shaft. Install the plate washer followed by the armature shaft to its position within the starter commutator end frame assembly before adding the new snap ring with snap ring pliers while keeping the snap ring below 5.0 mm (0.197 in.). Install the starter commutator end frame cover before placing the starter armature plate inside the starter yoke assembly where its keyway should align perfectly with the key inside the starter yoke. The starter yoke assembly must receive the starter commutator end frame through correct alignment by means of the convex cutout. The starter yoke assembly must have its provided key properly aligned with starting drive housing this enables attachment with 2 through bolts torquing to 6.0 N.m (61 kgf.cm, 53 in.lbf). The last step includes adding grease to the plunger and hook followed by hooking the plunger hook of the repair service starter kit onto the drive lever then inserting the plunger and return spring and securing the repair service starter kit with 2 screws tightened to 7.5 N.m (76 kgf.cm, 66 in.lbf). Moreover, attach the lead wire to the terminal with its nut torqued to 10 N.m (102 kgf.cm, 7.4 ft.lbf).