Starting System: Starter: Replacement

REPLACE CLUTCH ASSEMBLY
1. Disassemble the starter housing and the clutch assembly.
  1. Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar.
    
    Fig 1: Installing Starter Housing And Clutch Assembly To Brass Bar
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Push down the pinion gear.
  3. Using a plastic-faced hammer, tap down the stop collar.
    
    Fig 2: Tapping Down Stop Collar
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Using a screwdriver, pry out the snap ring.
    
    Fig 3: Prying Out Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove the stop collar, pinion and compression spring.
    
    Fig 4: Removing Stop Collar, Pinion And Compression Spring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Push down the starter housing, and remove the spring retainer.
  7. Remove the clutch shaft, compression spring and starter clutch from the starter housing.
    
    Fig 5: Removing Clutch Shaft
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Assemble the starter housing and the clutch assembly.
  1. Install the starter clutch, compression spring, and clutch shaft to the starter housing.
    
    Fig 6: Installing Starter Clutch, Compression Spring, And Clutch Shaft To Starter Housing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar.
    
    Fig 7: Installing Starter Housing And Clutch Assembly To Brass Bar
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Push down the starter housing, and install the spring retainer, compression spring, pinion gear and stop collar.
    
    Fig 8: Installing Spring Retainer, Compression Spring, Pinion Gear And Stop Collar
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Push down the pinion gear.
  5. Using snap ring pliers, install a new snap ring.
    
    Fig 9: Installing New Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Using pliers, compress the snap ring.
  7. Check that the snap ring fits correctly.
  8. Remove the starter housing and clutch assembly from the brass bar.
    
    Fig 10: Compressing Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Using a plastic-faced hammer, tap the clutch shaft and install the stop collar onto the snap ring.
    
    Fig 11: Installing Stop Collar Onto Snap Ring
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE FRONT BEARING
1. Using SST, remove the bearing.
  SST 09286-46011
  
  Fig 12: Removing Bearing Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, press in a new bearing.
  NOTE: Be careful of the bearing installation direction.
  
  SST 09820-00031
  
  Fig 13: Pressing New Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE REAR BEARING
1. Using SST, remove the bearing.
  SST 09286-46011
  
  Fig 14: Removing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a press, press in a new bearing.
  
  Fig 15: Pressing New Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
1. Remove the 3 bolts, end cover, gasket and plunger.
  Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
  
  Fig 16: Removing End Cover, Gasket And Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using vernier calipers, measure the contact plate for depth of wear.
  Maximum wear: 0.9 mm (0.035 in.)
  
  If the depth of wear is greater than the maximum, replace the contact plate.
  
  Fig 17: Measuring Contact Plate For Depth Of Wear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the terminal kit parts.
  1. Using SST, loosen the terminal nuts.
    SST 09810-38140
  2. Terminal C:
    Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
  3. Terminal 30:
    Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, and terminal insulator (inside).
    
    Fig 18: Loosening Terminal Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Temporarily install new terminal 30 kit parts:
  1. Install a new terminal insulator (inside).
    NOTE: Be careful to install the terminal insulator in the correct direction.
  2. Install a new contact plate.
  3. Install a new terminal bolt.
  4. Install a new O-ring.
  5. Install a new packing to a new terminal insulator, and install them.
    
    Fig 19: Installing New Terminal Insulator
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    HINT:
    
    Match the protrusion of the insulator with the indentation of the housing.
  6. Install a new wave washer.
    NOTE: Be careful to install the wave washers in the correct direction.
  7. Install a new terminal nut.
    Temporarily tighten the terminal nut.
5. Temporarily install new terminal C kit parts:
  1. Install a new terminal insulator (inside).
    NOTE: Be careful to install the terminal insulator in the correct direction.
  2. Install a new contact plate.
  3. Install a new terminal bolt.
  4. Install a new O-ring.
  5. Install a new terminal insulator (outside).
  6. Install a new wave washer.
    NOTE: Be careful to install the wave washer in the correct direction.
  7. Install a new terminal nut.
    Temporarily tighten the terminal nut.
    
    Fig 20: Installing New Terminal Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Tighten terminal nuts.
  1. Put a wooden block on the contact plate and press it down with a hand press.
    Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
    
    Press force: 981 N (100 kgf, 221 lbf)
    NOTE:
    Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure:
    
    Fig 21: Identifying Wooden Block On Contact Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Fig 22: Calculating Gauge Pressure Of Press
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
  2. Using SST, tighten the nuts to the specified torque.
    SST 09810-38140
    
    Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
    
    NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
    
    Fig 23: Tightening Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
8. Reinstall the plunger, a new gasket and the end cover with the 3 bolts.
  Torque: 2.5 N.m (26 kgf.cm, 23 in.lbf)
  
  Fig 24: Cleaning Contact Surfaces Of Contact Plate And Plunger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002