OEM 2006 Toyota 4Runner Starter Motor

2006 Toyota 4Runner Starter Motor Parts Q&A

• Q: How to service and repair the starter motor (1.6KW) on 2006 Toyota 4Runner?

  A: The repair service starter kit removal starts by unfastening the lead wire connection followed by unscrewing both securing screws that lead to extracting the kit along with the return spring and plunger. The technician needs to extract the starter yoke assembly through the detachment of two through bolts while pulling it out with the commutator end frame assembly. First detach the starter yoke assembly from the commutator end frame assembly and then proceed to remove the starter armature plate. Use a screwdriver to remove the starter commutator end frame cover before using snap ring pliers to take off the plate washer and snap ring allowing you to pull out the starter armature assembly from the commutator end frame assembly. Start by removing the three planetary gears before pulling out the starter center bearing clutch sub-assembly together with its drive lever set pin. Use an ohmmeter to check the starter armature assembly for commutator segment continuity as well as commutator-core coil core connection; replace the armature when no continuity exists and clean and correct any dirty or burned commutator surfaces using sandpaper (No.400) or a lathe. Executing the commutator length measurement with vernier calipers confirms it should stay shorter than 3.8 mm (0.150 in.) for a new installation. An inspection of the brush holders should verify two conditions: the holder must be longer than 9.0 mm (0.354 in.) and also no electrical connection should exist between the positive and negative brush terminals. Check planetary gear teeth and starter center bearing clutch for damage alongside wear and perform component replacement for defective parts. The clutch pinion gear must move without resistance in a clockwise direction but achieve a lock when rotated counterclockwise. A new center bearing clutch sub-assembly must be installed if these test results are not achieved. The starter repair service kit needs to be replaced whenever there is an issue with the plunger quick return test together with pull-in and hold-in coil continuity checks. The drive lever set pin must be placed first onto the starter center bearing clutch before installing the clutch and pin into the starter drive housing. Start by greasing the planetary gears followed by installing them into place together with a greased plate washer and armature shaft until they are securely fastened by a new snap ring. Place the starter armature plate next to align with the keyway before fixing the starter commutator end frame cover. The starter yoke assembly needs to be attached with two through bolts to the starter commutator end frame assembly while maintaining alignment then torquing them to 6.0 N.m (61 kgf.cm, 53 in.lbf). The last step involves applying grease to both the plunger and hook components after which you should hang the plunger hook onto the drive lever and install the plunger and return spring before securing the repair service starter kit with two screws torqued to 7.5 N.m (76 kgf.cm, 66 in.lbf). Finally, connect the lead wire to the terminal through the nut torqued to 10 N.m (102 kgf.cm, 7.4 ft.lbf).