Section 5 (Starting System (2ZR-FE)): Starter: Disassembly

WARNING: This page is about a different variant/trim than selected.

REMOVE MAGNET STARTER SWITCH ASSEMBLY
1. Remove the nut, then disconnect the lead wire from the magnet starter switch assembly.
  
  Fig 1: Locating Magnet Starter Switch Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 nuts from the starter drive housing assembly while holding the magnet starter switch assembly.
  
  Fig 2: Locating Magnet Starter Switch Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull the magnet starter switch assembly, and while lifting the front part of the magnet starter switch assembly, release the plunger hook from the drive lever and magnet starter switch assembly.
  
  Fig 3: Holding Magnet Starter Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY
1. Using a T25 "TORX" socket wrench, remove the 2 bolts.
  
  Fig 4: Locating Drive Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Pull out the starter yoke together with the starter commutator end frame assembly.
  
  Fig 5: Pulling Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 screws from the starter commutator end frame assembly.
  
  Fig 6: Locating Starter Commutator End Frame Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Pull the starter yoke assembly out of the starter commutator end frame assembly.
  NOTE: While holding down the lead wire, remove the starter commutator end frame.
  
  Fig 7: Pulling Starter Yoke Assembly Out Of Starter Commutator End Frame Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ARMATURE ASSEMBLY
1. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder.
2. Disconnect the 4 brushes, and remove the brush holder.
  
  Fig 8: Removing/Installing Brush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the starter armature assembly from the starter yoke assembly.
REMOVE STARTER ARMATURE PLATE
1. Remove the armature plate from the starter drive housing assembly or the starter yoke assembly.
  
  Fig 9: Identifying Starter Armature Assembly And Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 10: Identifying Starter Armature Plate, Starter Yoke Assembly And Housing Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PLANETARY GEAR
1. Remove the 3 planetary gears from the starter center bearing clutch sub-assembly.
  
  Fig 11: Locating Planetary Gears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
1. Remove the starter center bearing clutch sub-assembly with starter pinion drive lever from the starter drive housing assembly.
2. Remove the starter center bearing clutch sub-assembly, rubber seal, and starter pinion drive lever.