Question about Toyota 4Runner
Remove the battery terminals from the battery, take a look down where the starter is and locate the two bolts holding it in and the cables going to it. Determine if its easier to undo the bolts and cables from the top or underneath the car. One cable will have a 12mm nut holding it on, and the other will be a plug in type. Remove the cables and bolts, making sure when you remove the last one that the starter is not going to drop out onto the ground. Once you remove the starter place in in a vice, gripping on one of the mounting holes or around the alloy housing where it fits into the hole on the gearbox. Be sure not to grip in on the end with the two screws and long bolts, or anywhere near there, as you could cause some damage. Remove the three 8mm bolts from the solenoid, you wil notice the cover will spring out a little. Remove the cover and you will see the plunger and two contacts. Remove the plunger simply by pulling it out, take care not to lose the long spring. Check to see if the contacts are dirty or worn down, usually one side will wear down further. Check the copper ring on the plunger and see if it is worn down. A lot of the time you can get away with just replacing the contacts and sanding the ring on the plunger with light sandpaper. Remove one of the contacts at a time, do this by undoing the nut which holds the contact in place on the stud you removed the cable from when removing the starter from the vehicle. Remove the plastic insulator and rubber o'ring (if still intact) then remove the stud and contact as one. Be sure not to lose the plastic insulator on the inside. Lightly tap the stud, holding the contact and they will separate. Fit the new contact to the stud, and leave it loosely in. Refit the contact and stud, with the insulator to the solenoid housing. Re fit the external insulator and o'ring, followed by the nut. Tighten the nut will lightly tapping the contact to keep it flat in the solenoid. Do the nut up until the stud pulls firmly into the contact.
The second contact is done in much the same way, remove the cable that goes from the solenoid to the brushes in the side of the starter by undoing the nut holding it on, then the next nut, insulator etc.. The difference is the stud does not press fit into the contact. Remove the stud first by simply pulling it out from the inside. Then slide the contact out, ensuring the paper inulsulator is retained. Be careful not to damage the connection on the inside that goes down into the solenoid. Simply fit the new contact in reverse order, and once you have just about done it up, tap it flat lightly as per the other side. Do it up completely and re-fit the cable. Fit the either cleaned or replaced plunger being sure to oil the main sliding part of it lightly,and putting a dab of grease at the pointy end. Be sure to remember to fit the spring back in. Re fit the cover with the three bolts. You can test the starter with jumper cables from a battery. Place the black cable on the alloy body of the starter, and the red cable on the free stud, where you removed the cable on the vehicle. Using a piece of wire link the small terminal where the small wire came off on the vehicle to the red cable, being sure the starter is firmly held or secured in a vice. The starter will begin to turn the instant you make the connection so don't get a fright.. haha.
Refit the starter with bolts and cables, refit the battery terminals and presto.
If the starter fails to turn when you test it, there is likely a problem with a burnt out armature inside the starter. (unless you don't hear the distinctive click of the solenoid.) If this is the case, and it makes no noise whatsoever, there is either a worn brushes inside the starter, or the pull in winding or connection is broken on the solenoid
Posted on Mar 15, 2011
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Posted on Jan 02, 2017
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