OEM 2005 Toyota Avalon Starter Motor

2005 Toyota Avalon Parts Questions & Experts Answers

• Q: How to overhaul the starter motor on 2005 Toyota Avalon?

  A: Start by removing the repair service starter kit through lead wire disconnection and slow screw removal of two securing screws. Separate the starter yoke assembly by first unfastening two through bolts followed by pulling out the starter commutator end frame with the yoke until you can divide the yoke from the frame. The drive housing starter bearing cover must be taken off using a screwdriver while the starter armature plate should be removed from the starter yoke. Snag ring pliers combined with a plate washer easily allow you to remove the snapped ring and plate washer before pulling the starter armature out from the commutator end frame. Take out the three planet gears from the motor terminal starter kit. Check the plunger for quick return and measure resistance between terminals 50 and C (standard: below 1 Ohm) and between terminal 50 and the starter kit body (standard: below 2 Ohms) to determine replacement needs of the repair service starter kit. The starter armature assembly requires a resistance check between commutator segments (standard: less than 1 Ohm) and between commutator segment and armature coil core (standard: higher than 10 kOhms) to determine replacement needs. You must inspect the commutator surface for dirt or burning symptoms and smooth out unwanted marks with 400-grit sandpaper or leather material until you measure the commutator depth using vernier calipers (standard measures 3.1 mm but maximum width extends to 3.8 mm). The commutator needs replacement if the depth exceeds maximum values. Starter commutator end frame assembly inspection requires a brush length measurement check which should fall within 9.0 mm and 4.0 mm range while resistance across positive and negative brushes needs to be at least 10 kOhms; perform repairs and replacements when necessary. You should examine the starter clutch through its clutch pinion gear rotation in a counterclockwise motion to verify free motion and clockwise lockup functionality; replace if needed. High-temperature grease must be applied to the planet gears and pin parts on the planetary shaft before the setup of 3 planet gears into the motor terminal starter kit. The starter commutator end frame needs high-temperature grease on its plate washer and armature shaft before inserting the starter armature into position with a new snap ring and plate washer without letting the snap ring extend beyond 5.0 mm in length. When assembling the starter commutator end frame, start by placing the drive housing starter bearing cover on the frame. Then set and mount the starter armature plate onto the starter yoke before inserting the complete starter commutator end frame unit properly while ensuring the rubber component faces the grove inside the yoke to prevent any damage. Fasten two through bolts into the starter yoke which should align with the motor terminal starter kit before torquing them to 5.9 N.m. After applying high-temperature grease to both the plunger hook and plunger dip the plunger hook onto the drive lever hook then install both plunger and return spring before using two 7.5 N.m torqued screws to secure the repair service starter kit follow it by connecting the lead wire to the repair service starter kit with 9.8 N.m.