OEM 2005 Toyota Land Cruiser Starter Motor

2005 Toyota Land Cruiser Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2005 Toyota Land Cruiser?

  A: Service and repair of the starter motor begins with removing 2 dust protectors then loosening the lead wire nut from the magnetic switch terminal while applying 5.9 N.m (60 kgf.cm, 52 in.lbf) torque. The service requires removal of the 2 through bolts which require 9.3 N.m (95 kgf.cm, 82 in.lbf) torque for extraction followed by pulling out the field frame with armature from the magnetic switch assembly before aligning the field frame protrusion into the magnetic switch groove. A new O-ring needs to be used for the field frame after removing its existing O-ring during assembly. Follow these steps to detach the starter housing and clutch assembly and gear by unfastening 2 screws at 9.3 N.m (95 kgf.cm, 82 in.lbf). Next separate the starter housing from the return spring and idler gear and bearing as well as the starter clutch assembly by supplying grease to the return spring prior to placing it into the clutch shaft hole. The extraction of the steel ball through the clutch shaft hole requires a magnetic finger while applying grease during this process. The brush holder requires removal of 2 screws with O-ring and end cover from the field frame while applying 3.8 N.m (39 kgf.cm, 34 in.lbf) torque then discarding the O-ring and replacing it with a new one during assembly. Disconnect the brush wires of the brush holder keeping the spring elevated with a screwdriver while preventing any contact between positive lead wires and the frame. Apply Special Service Tool: 09286-46011 to remove the bearing and use it to press in a new one before installing the tool back. To replace the front bearing first use Special Service Tool: 09286-46011 then switch to Special Service Tool: 09820-00031 along with a press while paying attention to correct installation direction. Start by removing the end cover's 3 bolts followed by end cover removal while withdrawing gasket and plunger elements to inspect the contact plate for wear that requires replacement if it reaches 0.9 mm (0.035 in.). The technician must rotate both Terminal C and Terminal 30 terminal nuts with Special Service Tool: 09810-38140. Then replace the terminal parts keeping the insulator and wave washer properly oriented before tightening the terminal nuts to 17 N.m (170 kgf.cm, 13 ft.lbf). Tighten the terminal nuts by using Special Service Tool: 09810-38140 on the contact plate while keeping it under pressure from a wooden block (20 x 37 x 40 mm) and providing a force of 981 N (100 kgf, 221 lbf), then tighten the nuts to a torque of 17 N.m (170 kgf.cm, 13 ft.lbf) while being cautious to prevent insulator cracking. Install the magnetic switch end cover followed by the plunger and new gasket using an end cover then secure the clamp with three bolts applying 3.6 N.m (37 kgf.cm, 32 in.lbf) torque. Clean contact surfaces of the plate and plunger before this installation. Assembling the gearbox requires following the opposite order of disassembly steps while applying high-temperature grease to lubricate the bearing and gears.