Section 527 (Starting System): Starter: Disassembly

WARNING: This page is about a different car, the 2005 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE 2 DUST PROTECTORS
REMOVE FIELD FRAME AND ARMATURE
1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
  Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2. Remove the 2 through bolts.
  Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
  
  Fig 1: Identifying Start Dust Protectors, Trough Bolts & Lead Wire Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the field frame together with the armature from the magnetic switch assembly.
  NOTE: At the time of notice, align the protrusion of the field frame with the groove of the magnetic switch.
  
  Fig 2: Identifying Field Frame Protrusion & Magnetic Switch Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring from the field frame.
  HINT:
  
  At the time of assembly, use a new O-ring.
REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
1. Remove the 2 screws.
  Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
  
  Fig 3: Locating Starter Housing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove these parts from the magnetic switch assembly:
  1. Starter housing
  2. Return spring
  3. Idler gear
  4. Bearing
  5. Starter clutch assembly
  HINT:
  
  At the time of assembly, apply grease to the return spring and insert the return spring into the clutch shaft hole.
  
  Fig 4: Exploded View Of Starter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.

HINT:

At the time of assembly, apply grease to the steel ball and insert the steel ball into the clutch shaft hole.

Fig 5: Removing Steel Ball
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRUSH HOLDER
1. Remove the 2 screws w/ O-ring and the end cover from the field frame.
  Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
2. Remove the O-ring from the field frame.
  HINT:
  
  At the time of assembly, use a new O-ring.
  
  Fig 6: Locating End Cover Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.
NOTE: Check that the positive (+) lead wires are not grounded.
REMOVE ARMATURE FROM FIELD FRAME