Starters - NIPPONDENSO Direct Drive: Overhaul: Disassembly

Disconnect field coil wire from starter solenoid main terminal and remove solenoid attaching bolts. Remove solenoid by moving it up and down to unhook unit from drive lever.
Remove bearing cover and pull out armature shaft lock plate, washer, seal and spring. Remove through bolts, commutator end frame, brush holder and yoke.
Remove drive lever set bolt, rubber piece, plate, armature and drive lever from housing. Remove pinion stop collar from armature shaft end and remove starter clutch.

STARTER PERFORMANCE SPECIFICATIONS

Model

No Load Test ⁽¹⁾

Lock Test

Amps.

RPM

Amps.

Volts

Torque

D77Z

below 50

over 5000

.....

2970

below 50

over 5000

below 600

7.7

over 9.4 ft.lbs.

4210

below 50

over 5000

below 600

7.7

over 9.4 ft.lbs.

4721

below 60

over 5000

below 600

7.0

over 13.0 ft.lbs.

657-016

below 70

over 6000

below 380

5.5

over 6.15 ft.lbs.

60041

below 50

over 5000

.....

60061

below 50

over 5000

.....

24080

below 55

over 3500

below 450

8.5

9.4 ft.lbs.

42020

below 50

over 5000

.....

45033

below 50

over 5000

.....

34052

below 50

over 5000

.....

33020

below 50

over 5000

.....

⁽¹⁾	At 11.5 volts on Toyota; 11 volts all others.