Starting System: Starter: Disassembly

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: Removing Nut & Disconnecting Lead Wire From Magnetic Switch Terminal
  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 assembly, align the protrusion of the field frame with the groove of the magnetic switch.
4. Remove the O-ring from the field frame.
  HINT:
  
  At the time of assembly, use a new O-ring.
  
  Fig 2: Pulling Out Field Frame Together With Armature From Magnetic Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Removing Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove these parts from the magnetic switch assembly:
  
  Fig 4: Removing These Parts From Magnetic Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Starter housing
  2. Return spring
  3. Idler gear
  4. Bearing
  5. Starter clutch assembly
    HINT:
    
    At the time of assembly, please refer to the following items. Apply grease to the return spring and insert the return spring into the clutch shaft hole.
REMOVE STEEL BALL
1. 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 From Clutch Shaft Hole Using Magnetic Finger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRUSH HOLDER
1. Remove the 2 screws with O-ring and the end cover from the field frame.
  Torque: 3.8 N*m (39 kgf*cm, 34 in.*lbf)
  
  Fig 6: Removing Screws With O-Ring & End Cover From Field Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the field frame.
  HINT:
  
  At the time of assembly, use a new O-ring.
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