Starting System: Starter: Reassembly

NOTE: Use high temperature-resistant grease to lubricate the bearings and sliding parts when assembling the starter.

INSTALL INTERNAL GEAR AND PLANETARY CARRIER SHAFT
1. Apply grease to the internal gear touching the shock absorber and planetary gears.
  
  Fig 1: Applying Grease To Internal Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the hollow of the internal gear with the protrusion inside the shock absorber.
3. Insert and turn the internal gear so that it interlocks with the shock absorber.
  
  Fig 2: Aligning Hollow Of Internal Gear With Protrusion Inside Shock Absorber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply turbine oil to the center bearing.
5. Apply grease to the plate washer, and install it to the planetary carrier shaft.
6. Install the planetary carrier shaft to the shock absorber.
  
  Fig 3: Installing Planetary Carrier Shaft To Shock Absorber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using snap ring pliers, install the plate washer and snap ring.
Fig 4: Installing Plate Washer And Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER CLUTCH
1. Apply grease to the bushing and spline of the starter clutch stop collar.
2. Place the starter clutch and stop collar on the planetary carrier shaft.
  
  Fig 5: Placing Starter Clutch And Stop Collar On Planetary Carrier Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply grease to the snap ring, and install it to the planetary carrier shaft groove.
4. Using a vise, compress the snap ring.
  
  Fig 6: Compressing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Hold the starter clutch, tap the planetary carrier shaft and install the stop collar onto the snap ring with a plastic-faced hammer.
Fig 7: Tapping Planetary Carrier Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PLANETARY GEARS
1. Apply grease to the planetary gears and flange pin parts of the planet carrier shaft.
2. Install the plate washer and 3 planetary gears.
3. Align the cutout of the plate with the protrusion inside the shock absorber, and install the plate.
Fig 8: Installing Planetary Gears
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE LEVER AND STARTER CLUTCH WITH SHOCK ABSORBER
1. Apply grease to the drive lever touching the starter pivot part of the drive lever.
2. Install the drive lever to the starter clutch.
  
  Fig 9: Installing Drive Lever To Starter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the protrusion of the shock absorber with the cutout of the drive housing and install them.
PLACE ARMATURE INTO FIELD FRAME

Fig 10: Aligning Protrusion Of Shock Absorber With Cutout Of Drive Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRUSH HOLDER
1. Place the brush holder in position on the armature.
2. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.
  NOTE: Check that positive (+) lead wires are not grounded.
3. Install a new O-ring to the groove of the field frame.
4. Apply turbine oil to the bearing of the end cover.
5. Install the end cover to the field frame with 2 screws.
  Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
Fig 11: Holding Brush Spring Back
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FIELD FRAME AND ARMATURE ASSEMBLY
1. Install a new O-ring to the groove of the field frame.
2. Align the cutout of the field frame with the protrusion of the shock absorber.
3. Install the field frame and armature assembly with the 2 through bolts.
  Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
Fig 12: Aligning Cutout Of Field Frame With Protrusion Of Shock Absorber
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MAGNETIC SWITCH
1. Hang the plunger of the magnetic switch to the drive lever from the upper side.
2. Install the magnetic switch with the 2 nuts.
  Torque: 8.3 N.m (85 kgf.cm, 73 In.lbf)
3. Connect the lead wire to the terminal, and install the nut.
  Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)
Fig 13: Installing Magnetic Switch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002