Starter - Reduction Gear Toyota 4Runner I

DESCRIPTION

Starter is a 12-volt, 4-brush, solenoid-actuated, gear reduction-type, equipped with an overrunning clutch. The brush holder assembly retains brushes and springs in the starter housing.

APPLICATION

No Load Test (All Models)

1. Connect ammeter in series with starter motor and 12-volt battery. (Scheme 1) Connect voltmeter in parallel with battery and observe readings.
2. Starter should spin smoothly at 3000 RPM or more with current draw below 90 amps (180 amps on diesel engines) at 11.5 volts.

Ammeter & Voltmeter Hook-Up for No Load Test. Scheme 1

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

DISASSEMBLY

1. Disconnect solenoid switch wire(s). Remove bolts and remove field frame with armature from solenoid switch. Remove "O" ring and felt seal.
2. Remove starter gear housing screws from solenoid switch. Pull out clutch assembly and gears. Remove ball from clutch shaft hole or from magnetic switch. Remove brushes from brush holder. Pull armature out of field frame.
3. Clean parts with air pressure. DO NOT clean starter and/or components in solvent. Check all parts for wear or damage.

Brushes & Springs

1. Check brush length. If less than specification, replace brushes. See «BRUSH LENGTH SPECIFICATIONS»(/toyota/4runner/i-1984-1989/remont/starter/#starter-reduction-gear) table.
2. Check condition of brush holders, springs, spring clip and insulation between positive and negative holders and repair or replace as needed.

BRUSH LENGTH SPECIFICATIONS

Commutator

1. Inspect commutator for roughness. If surface is pitted stepped or grooved, it should be lightly sanded with No. 400 sandpaper. Check commutator for out-of-round.
2. If out-of-round is more than .002" (.05 mm), turn the commutator on a lathe until out-of-round is within specification.
3. Wear or cutting limit of commutator is 1.22" (31 mm) for Cressida and Supra, or 1.14" (29.0 mm) for all others.
4. If worn less than .008" (.20 mm), insulating mica should be undercut to a depth of approximately .028-.035" (.71-.89 mm) on Toyota diesel models, or .015-.031" (.40-.80 mm) on all other models.

Armature Coil

1. Check commutator and armature coil core for continuity. If continuity exists, replace armature. Check armature with a growler for shorts. Replace if shorted.
2. Check for continuity between segments on commutator. If no continuity exists, replace armature.

Field Coil

Check field coil for open circuits. There should be continuity between lead wire and field coil brush lead. If not, replace field coil. Check for continuity between field coils and end frame. If continuity exists, replace field coil.

Solenoid Pull-In Coil Test

Connect 2 battery negative leads to "C" terminal on Toyota and ground. Connect a 12-volt battery positive lead to solenoid terminal "50" on Toyota. (Scheme 2) Plunger should extend firmly. If not, replace solenoid.

Solenoid Pull-In Coil Test Connect battery positive to "ST" terminal (terminal "50". Scheme 2

Solenoid Hold-In Coil Test

After pull-in testing, disconnect battery negative lead from "C" terminal on Toyota. Plunger should remain extended. If not, replace solenoid. (Scheme 2)

REASSEMBLY

To reassemble, reverse disassembly procedure. Coat all sliding or moving surfaces of shaft splines, bushings and solenoid with multi-purpose grease. Apply molybdenum disulfide grease to clutch assembly cavity to retain steel ball.

View of Nippondenso Reduction Gear Starter Mitsuba reduction gear starter is similar. Scheme 3

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• BRUSH LENGTH SPECIFICATIONS