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Starter motor rebuild. with lots of pics

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  • #16
    Originally posted by StormyKnight View Post
    This is a great write-up!

    One thing i noticed in the pics is the engine oil on the outside of the starter. When the oil filter is changed on this model engine, some oil can leak down & onto the starter motor causing it to fail. There is a pipe that should drain the oil away but often it becomes blocked. Just another thing to be aware of when changing oil on the car. 8)
    I have this issue, I thought it was a bog hole, but now I think a new reason is the cause, the oil filter change !
    This weekend I'll be under the car doing the starter motor cleanup!
    Thanks again

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    • #17
      Ok read through the post, just need to figure out where it all is (under the oil filter it seems) and how to remove it.
      Its a 2004 with 191K on the clock so I am tipping it will need the full monty as Jeff has shown below !
      You are a good man Jeff !
      Another Pradopoint member told me - Mud and Water = $$$$
      He was not wrong. But if you do things yourself it (hopefully) changes the equation to
      Mud and Water = time!

      Comment


      • #18
        Prado 120 series, Diesel, 2004

        Great thread, pretty much took 2 hours, most of which was getting it off. This post really only starts after you get the motor out, so I thought I would just write up my experience in getting the motor out and confirm there are two bolts holding it in place.
        - Took the bash plates off
        - Access from underneath, quite far back looking up towards the front, arms up through there and through further forward up near drive shafts
        - pulled off the plastic covering on the big lead and unbolted the cable from the side of the solenoid
        - pushed the bottom in of the other plug and wiggled that plug off -was quite easy

        The whole unit is held to the gear box/transmission case with 2 bolts

        The top bolt is actually part of the whole starter and solenoid assembly and goes through the gearbox and has a nut on the other side. This nut was accessible with a ratchet and socket to loosen it (VERY fricken tight), then it was quite easy to remove by hand.

        I had a lot more trouble with the bottom one and had to use a longer lever to get it loose, once it was loose I supported it and removed the bottom nut and bolt by hand, whilst the whole unit was basically moving around.

        I manoeuvred the unit back a bit until the shaft and small gear were clear of the transmission, then brought the whole unit down diagonally to wards the back of the car and out. It fits quite easily through that space.

        I didn't do a complete rebuild as below post, but just took out the plunger and cleaned up the connections and the plunger etc exactly as described below. It actually didn't look all that bad really, surprising I was having as much trouble as I was (getting the clunk 1 in every 4 starts). Perhaps the bottom contact was a bit worse than the top.

        10 minutes later I was putting it back together. one issue I had was with the ball bearing where the spring goes in, I notice the spring was being caught by it or something. I turned it up side down and just moved the ball bearing around a bit and then but the plunger with spring in and pressed it firmly in, it seemed to move nicely in and out pushing out the starter gear on the other side and springing back

        Once back together put it back in the car same way it came out. tightened up, cables back on and tested it about 10 times - 100%!

        Put bash plates back on and so far it has been great !

        Thanks again for the write up. Great stuff - I'll bet that would have cost $500-1000 in a shop to get done!
        Plums
        Junior Member
        Last edited by Plums; 24-10-2015, 02:58 PM.

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        • #19
          Just a quick revisit of this old thread. Glad to see it has helped a few people.
          Reminds me of my safari in Africa. Somebody forgot the corkscrew and for several days we had to live on nothing but food and water.
          W. C. Fields (1880 - 1946)

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          • #20
            can I get away with just using grease on throw out gear threads and one way bearing parts?

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            • #21
              Just an option for removal.
              I had a similar issue after water crossing with starter intermittently starting.
              ** I have a V6 2003 grande***
              I jacked my vehicle up from the passenger front and removed the passenger front wheel. I then extracted the starter out from within the wheel arch. very simple. Remove 12mm nut from cable. remove wire connector. Remove 2 x 14mm bolts holding starter. remove starter out from wheel arch.
              PS: I removed the slash rubber from within the wheel arch and this allowed the whole operation to take place from within the wheel arch.
              I reconditioned the starter and had it back in the vehicle within 2hrs total job.

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              • #22
                Nice one!

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                • #23
                  Originally posted by Daza View Post
                  Just an option for removal.
                  I had a similar issue after water crossing with starter intermittently starting.
                  ** I have a V6 2003 grande***
                  I jacked my vehicle up from the passenger front and removed the passenger front wheel. I then extracted the starter out from within the wheel arch. very simple. Remove 12mm nut from cable. remove wire connector. Remove 2 x 14mm bolts holding starter. remove starter out from wheel arch.
                  PS: I removed the slash rubber from within the wheel arch and this allowed the whole operation to take place from within the wheel arch.
                  I reconditioned the starter and had it back in the vehicle within 2hrs total job.
                  I did mine the same way but just put a new one in as had no time to wait for parts and could get one couriered out same day. Pulled the old one apart later and found brushes worn right down. Genuine set for $35 already mounted in the end cap and now I have a complete spare for later.
                  1997 petrol auto, 430 000km. Still going strong.
                  2004 petrol auto, 233 000km. Cracked dash and no help from Toyota!

                  Comment


                  • #24
                    double post
                    1997 petrol auto, 430 000km. Still going strong.
                    2004 petrol auto, 233 000km. Cracked dash and no help from Toyota!

                    Comment


                    • #25
                      Thanks for the write ups guys. My 2004 V6 GXL starter has decided to go on winter break so i'll be pulling it out after work & replacing it with a new one. I'll recondition the old one & keep it as spare. i'll update you on how the changeover goes.
                      The Brother
                      Lurker
                      Last edited by The Brother; 15-06-2017, 04:30 PM.

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                      • #26
                        My 2005 V6 failed to start on three occasions after I'd stopped for a short period. There was no clicking from the solenoid and all the dash lights would go out, except for the warning lights. My first thought was the battery, but even switching the second on to jump start didn't help.
                        Usually it started after cooling down, but it didn't the third time and the only way to start it was to tap on the starter motor while turning the key. The fault had to be the solenoid or starter.
                        After reading this post I thought I'd be cleaning the contacts and overhauling the starter.
                        I then discovered the solenoid was a sealed unit and started doing some tests. The coil resistance to earth measured 1.5 ohms and 1 ohm to the starter terminal. Next was a 12v test. With power applied the piston wouldn't actually click in until I pushed it within 5mm of the contacts. It was also only drawing 11 amps.
                        I couldn't buy a solenoid locally, so I bought a complete starter and found the current draw was 38 amps which also s very reassuring clunk.
                        One additional issue was the broken retaining clip on the trigger wire to the solenoid. Toyota only sell the attached wiring loom for $650.
                        The final result was new starter installed, cable tie on the trigger wire and the sweet sound of a V6 firing up.

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                        • #27
                          I could do with some help on identifying the issue with mine fellas please...

                          It's an 05 VX 4.0 V6, and it has the feature where you just turn the key and let it go and it starts the car for you.

                          What is happening is when I turn the key it kicks the solenoid and the starter to the fly wheel and turns the engine but then after a second or so it releases from the fly wheel and the starter motor keeps turning. I am guessing the solenoid is not holding it's position when engaged?

                          I am hoping that someone is going to tell me that it because of all the 4wdriving I do that the solenoid is dirty or something is sticking and I just need to pull it our and clean it????

                          Comment


                          • #28
                            I'd pull it out, strip it down and give it a good clean for starters. Pretty easy to remove through the left wheel arch. Philips head screws on the solenoid can be a bitch to release without stripping the heads. Best attacked with an impact driver.
                            1997 petrol auto, 430 000km. Still going strong.
                            2004 petrol auto, 233 000km. Cracked dash and no help from Toyota!

                            Comment


                            • #29
                              Did it, done it, works great again. Thanks for the tip going through the wheel arch, made it much easier. Tried an impact screw driver and stripped the tread straight away. I found the easiest way was to spray WD40 and give it quite a few taps with the hammer to loosen it off and they came out easily. Only bit I wasn't sure about was whether to re-grease it when putting it back. I cleaned out all the sprockets in the starter motor an re-greased them as they have metal to plastic contact and are not exposed , but the rest of it I didn't bother as I found from using Grease in the past has caused it to attract dirt and clog up again and have the same problem.

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                              • #30
                                Thanks helps no end!!

                                Comment

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