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Reassembly [10/2017 - ]: Procedure

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  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY 
    1. Apply high-temperature grease to the drive lever set pin as shown in the illustration.
      GTY461200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the drive lever set pin onto the starter center bearing clutch sub-assembly.
      GTY831296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Drive Lever Set Pin
      *2 Starter Center Bearing Clutch Sub-assembly
    3. Install the starter center bearing clutch sub-assembly with drive lever set pin to the starter drive housing assembly.
  2. INSTALL PLANETARY GEAR 
    1. Apply high-temperature grease to the planetary gears and planetary shaft pins.
      GTY778326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Install the 3 planetary gears.
  3. INSTALL STARTER ARMATURE ASSEMBLY 
    1. Hold the starter commutator end frame assembly in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vice.

    2. Apply high-temperature grease to the new snap ring, washer and bearing as shown in the illustration.
      GTY837712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    3. Apply high-temperature grease to the armature shaft.
      GTY825570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    4. Install the starter armature assembly to the starter commutator end frame assembly.
    5. Using snap ring pliers, install the washer and a new snap ring.
      GTY458197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Snap Ring Pliers
      NOTE:
      • Be sure to install the snap ring in the armature shaft groove securely.
      • Be sure to properly install the snap ring because it expands easily.
    6. Using a vernier caliper, measure the length of the snap ring opening.
      GTY465185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Length

      Maximum Length

      5.0 mm (0.197 in.)

      If the length is greater than the maximum, replace the snap ring with a new one.

  4. INSTALL STARTER COMMUTATOR END FRAME COVER 
    1. Install the starter commutator end frame cover to the starter commutator end frame assembly.
  5. INSTALL STARTER ARMATURE PLATE 
    1. Insert the starter armature plate to the starter yoke assembly.
      GTY471097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Keyway
      *b Key
    2. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.
  6. INSTALL STARTER YOKE ASSEMBLY 
    1. Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly.
      GTY465972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rubber
      *b Cutout
    2. Install the starter commutator end frame assembly to the starter yoke assembly.
      NOTE:

      The magnet switch of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet switch to break.

  7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY 
    1. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.
      GTY461831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Install the starter yoke assembly with the 2 through bolts.

      Torque: 6.0 N.m (61 kgf/cm, 53 in.lbf) 

  8. INSTALL REPAIR SERVICE STARTER KIT 
    1. Apply high-temperature grease to the plunger.
      GTY786023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      High-temperature Grease
    2. Hang the hook of the plunger on the drive lever set pin.
    3. Install the plunger and return spring.
    4. Install the magnet switch with the 2 screws.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

    5. Connect the lead wire to the magnet switch with the nut.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

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