STARTER (for AWD): Reassembly

INSTALL PLANETARY GEAR
1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration.
2. Install the 3 planetary gears.
INSTALL STARTER ARMATURE PLATE
1. Align the tab of the starter armature plate fits over the projection of the starter center bearing clutch.
  
  Fig 1: Identifying Starter Armature Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the plate to the center bearing clutch.
INSTALL STARTER ARMATURE ASSEMBLY
1. Install the starter armature to the starter center bearing clutch sub-assembly.
  
  Fig 2: Identifying Starter Armature Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER YOKE ASSEMBLY
1. Align the claw of the center bearing clutch with the groove of the starter yoke.
2. Install the starter yoke.
INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
1. Install the starter brush holder assembly.
  
  Fig 3: Identifying Starter Yoke Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder.
3. Connect the 4 brushes.
  
  Fig 4: Removing Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Align the starter commutator end frame rubber with the groove of the starter yoke.
  
  Fig 5: Aligning Starter Commutator End Frame Rubber With Groove
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the starter commutator end frame with the 2 screws.
  Torque: 3.8 N*m (39 kgf*cm, 33 in.*lbf)
  
  Fig 6: Installing Starter Commutator End Frame And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER DRIVE HOUSING ASSEMBLY
1. Apply high-temperature grease to the starter pinion drive lever, as shown in the illustration.
  
  Fig 7: Locating High-Temperature Grease Applying Areas On Starter Pinion Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the pinion drive lever to the center bearing clutch.
  
  Fig 8: Locating Starter Pinion Drive Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Align the claw of the starter yoke with the groove inside the drive housing.
  
  Fig 9: Aligning Claw Of Starter Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a T30 "TORX" socket wrench, install the drive housing with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 10: Locating Drive Housing With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER MAGNETIC SWITCH ASSEMBLY
1. Temporarily install the magnetic switch by hooking its tip to the upper side of the pinion drive lever.
2. Install the 2 nuts.
  Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
  
  Fig 11: Locating Starter Magnetic Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the lead wire to the terminal with the nut.
  Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
  
  Fig 12: Locating Lead Wire And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002