OEM Toyota MR2 Spyder Starter Motor

Toyota MR2 Spyder Starter Motor Parts and Q&A

• Starter
  28100-22060-84
  Q: How to service and repair the starter motor on Toyota MR2 Spyder?

  A:

  Start the starter motor repair process by completing component disassembly through the following steps: take out the nut and disconnect the lead wire from the magnetic switch terminal followed by removing all field frame through bolts to extract the field frame with its embedded armature from the magnetic switch assembly then remove the O-ring followed by the 2 screws and end cover from the field frame, and lastly remove the O-ring on the field frame. A screwdriver should be used to secure the spring tank while you disconnect the brush from the brush holder so you can remove the 4 brushes together with the brush holder. Begin by removing the 2 bolts to disconnect the starter housing and its included components of idler gear, bearing along with the clutch assembly and return spring. A magnetic finger will be used to extract the steel ball from the clutch shaft hole. After applying high-temperature grease on bearings and gears you should install the armature on the magnetic switch assembly while adding grease to the armature bearings. Place the steel ball into the clutch shaft hole after it receives grease before you mount the starter housing with its clutch assembly and gears while using grease for the return spring and placing it within the magnetic switch hole prior to securing the starter housing at a torque level of 5.9 N.m (60 kgf.cm, 52 in.lbf) to the magnetic switch with 2 bolts. You should install a new O-ring to the field frame groove where it will align with the magnetic switch before installing the O-ring. Place the brush holder onto the field frame before using a screwdriver to keep the brush spring back and connecting the brushes with proper orientation between positive (+) leads and ground. The process requires installation of a new O-ring inside the field frame groove followed by attachment of the end cover through two screws tightened to 1.5 N.m torque (15 kgf.cm, 13 in.lbf). The field frame and armature assembly requires two through bolts tightened to 5.9 N.m torque (60 kgf.cm, 52 in.lbf). Furthermore, lead wire connection to terminal C needs a nut tightened to 5.9 N.m torque (60 kgf.cm, 52 in.lbf). First remove the bearing through the use of Special Service Tool: 09286-46011 before pressing in new front and rear bearings using Special Service Tool: 09820-00030 with a press. The replacement process requires removing all 3 bolts, end cover, gasket, and plunger while measuring the contact plate wear to check if replacement is needed because the maximum allowable wear is 0.9 mm (0.035 in.). The technician utilizes Special Service Tool: 09810-38140 to untighten terminal nuts before replacing Terminal C and Terminal 30 terminal kit components by placing temporary new terminal parts while maintaining proper terminal insulator placement. Tighten terminal nuts by pressing a wooden block against the contact plate until it reaches 981 N (100 kgf, 221 lbf) force and applying 17 N.m (170 kgf.cm, 12 ft.lbf) torque with a goal of insulator preservation. The contact plate and plunger require cleaning of their contact surfaces and the magnetic switch end cover installation involves placement of the plunger and new gasket followed by securing the 3 bolts with a torque of 2.5 N.m (26 kgf.cm, 23 in.lbf).