Toyota Pick-ups/Land Cruiser/4Runner 1970-1988

Starter

Print

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7

On some models with automatic transmission, it may be necessary to disconnect the throttle rod.

  1. Disconnect the negative (-) battery cable at the battery, then disconnect the positive (+) battery cable at the starter.
  2.  
  3. Disconnect the remaining electrical connections at the starter solenoid.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Starter mounting-all models similar

  1. Remove the two nuts holding the starter to the bell housing and pull the starter toward the front of the vehicle.
  2.  
  3. To install the unit, insert the starter into the bell housing being sure that the starter drive is not jammed against the flywheel. Tighten the attaching nuts and replace all electrical connections making the battery connection the last.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Removing the starter electrical connection



Click image to see an enlarged view

Fig. Fig. 3: View of the starter electrical connection (lower) and battery connection (upper)



Click image to see an enlarged view

Fig. Fig. 4: Removing the battery electrical connection



Click image to see an enlarged view

Fig. Fig. 5: Removing the starter mounting bolts



Click image to see an enlarged view

Fig. Fig. 6: Removing the starter assembly from the vehicle



Click image to see an enlarged view

Fig. Fig. 7: Installing the starter assembly

OVERHAUL



See Figures 8, 9 and 10

Solenoid Replacement-Direct Drive Type
  1. Remove the starter.
  2.  
  3. Unscrew the two solenoid switch (magnetic switch) retaining screws.
  4.  
  5. Remove the solenoid. In order to unhook the solenoid from the starter drive lever, lift it up at the same time that you are pulling it out of the starter housing.
  6.  
  7. Installation is in the reverse order of removal. Make sure that the solenoid switch is properly engaged with the drive lever before tightening the mounting screws.
  8.  

Brush Replacement
DIRECT DRIVE TYPE
  1. Remove the starter.
  2.  
  3. Remove the solenoid (magnetic switch).
  4.  
  5. Remove the two end frame cap mounting bolts and remove the end frame cap.
  6.  
  7. Remove the O-ring and lock plate from the armature shaft groove and then slide the shims off the shaft.
  8.  
  9. Unscrew the two long housing screws (they are found at the front of the starter) and carefully pull off the end plate.
  10.  
  11. Using a screwdriver, separate the brushes from the brush holder.
  12.  
  13. Slide the brush holder off of the armature shaft.
  14.  
  15. Crush the old brushes off of the copper braid and file away any remaining solder.
  16.  
  17. Fit the new brushes to the braid and spread the braid slightly.
  18.  

Use a soldering iron of at least 250 watts.

  1. Using a radio-grade solder, solder the brush to the braid. Grip the copper braid with flat pliers to prevent the solder from flowing down its length.
  2.  
  3. File off any extra solder and then repeat the procedure for the remaining three brushes.
  4.  
  5. Installation is in the reverse order of removal.
  6.  

When installing the brush holder, make sure that the brushes line up properly.

REDUCTION GEAR TYPE
  1. Remove the starter.
  2.  
  3. Disconnect the lead from the solenoid (magnetic switch) terminal.
  4.  
  5. Unscrew the two mounting bolts and remove the field frame assembly from the solenoid housing.
  6.  
  7. Remove the O-ring and the felt seal.
  8.  
  9. Unscrew the mounting screws and remove the starter housing from the solenoid housing.
  10.  
  11. Pull out the clutch assembly and then remove the pinion and idler gears.
  12.  
  13. Remove the steel ball from the clutch shaft hole.
  14.  
  15. Using a screwdriver, separate the brush and brush spring and remove the brush from the brush holder.
  16.  
  17. Install the four new brushes onto the brush holder using a screwdriver to hold the brush spring back.
  18.  

Make sure that the positive lead wires are not grounded.

  1. To reassemble, apply a dab of grease to the steel ball and insert it into the clutch shaft hole. Reverse the disassembly procedure starting with Step 6. Apply grease to the idler gears before assembly, and make sure the gears mesh during assembly.
  2.  

Starter Drive Replacement
DIRECT DRIVE TYPE
  1. Perform Steps 1-7 of the Brush Replacement-Direct Drive Type procedure.
  2.  
  3. Pull the field frame away from the drive housing and remove it.
  4.  
  5. Remove the drive lever pivot bolt from the drive housing.
  6.  
  7. Pull the armature from the drive housing.
  8.  
  9. Take a 14mm socket and slide it over the armature shaft until it rests on the stop collar.
  10.  
  11. Tap the stop collar down with a hammer.
  12.  
  13. Pry off the exposed stop ring and then remove the stop collar from the shaft.
  14.  
  15. Remove the starter drive clutch assembly.
  16.  
  17. Installation is in the reverse order of removal.
  18.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of a direct drive starter assembly



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of a reduction gear starter assembly



Click image to see an enlarged view

Fig. Fig. 10: Simplified no-load test

 
label.common.footer.alt.autozoneLogo