Announcement

Collapse
No announcement yet.

Starter motor rebuild. with lots of pics

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • Starter motor rebuild. with lots of pics

    Hi All.

    After my last outing in the bush I have had to do a few maintenance items due to being in the deep water too long.

    This time it was the Starter Motor.

    After the trip I had a few failed attempts at starting my Diesels engine.
    It would make a loud "CLACK" sound but not rotation noises, and definetly no engine noise. It would mostly start the next time I turned the key but after a few misses this last week I decided to pull the starter off and check it out.
    I rang Matt White (some of you would remember him as a past and hopefully future prado owner, and a handy mechanic who had a hand in pioneering the "TECH DAYS") I had a few questions to ask before I attempted this and he was spot on with his information.

    Before anything is to be attempted, a few tools will be requiered.
    12mm spanner, 17mm ring spanner, 17mm ratchet spanner would help. 8mm socket, phillips head screw drivers, small (ph2) and large (?) A bearing puller and I used 2 6004 rubber sealed bearings and a bit of grease.

    Before starting the battery needs to be disconnected. as there is a direct power supply to the main terminal on the starter.
    Disconnect the cable from the battery (12mm spanner) and remove 1 screw and 1 nut that hold the starter in.
    The starter is a little tricky to get out of the engine bay, I took mine out from underneath.

    It doesnt look too bad considering its at the lower side of the engine.
    Remove the 3 screws that retain the small cover over the end of the coil, it will have a small amount of spring pressure pushing on it. It has a rubber seal so dont damage this unless you want to buy a new one. I removed the wire to the motor for more access to these screws.
    Inside you will see the end of the plunger.

    Remove the plunger, have a look at it and check the condition of the springs and the contact surfaces as this is where the motor gets its power through, mine were horrible, hence the clunk sound but no rotation, the coil was pulling the plunger and closing the contacts but no power was getting through.
    The contact surface of the plunger is spring loaded as well, the surface is just at the end of my thumb.

    The contacts can be seen below, one on the left and one on the right of the hole through the coil. The one on the left is from the battery and the one on the right is to the motor. These as you can see need a good clean.

    Remove the motor by undoing the two screws (10mm heads) check the oring under the heads of the screws. A good clean needs to be done in here as well.


    Now remove the 2 phillips head screws to split the reduction gearbox, these were very tight, I dont have a impact driver so I heated the area that the threads screw in and they came out OK.



    This is the back of the one way clutch and pinion gear, just a firm tug on this should bring it out of the housing. And if you notice on the table, there is water.
    That stuff would have been in there for about 3 weeks :shock:

    The one way clutch and pinion assembly

    Grab the bearing puller and pull back the pinion gear, this will reveal the retaining clip.

    Remove the clip and collar.

    Pull out the inner drive shaft.

    I then pull the bearings of the outer shaft. The large gear is the one way clutch, it spins on the outer shaft ( well should do) this area was gummed up pretty bad. In need of a good clean.

    Inside the one way clutch.

    I gave all this a good clean and greased every thing, It went together alot better and everything moved freely. Much happier. oh and used lanotec spray.
    The one way clutch and pinion assembly. make sure the oneway clutch goes back on the right way now or it will not start the car...

    Motor with cleaned Commutator, cleaned and lanolined brush holders and brush springs etc. notice the cleaned and lanolined contacts and reduction gear housing in the background, alot cleaner yes???

    A cleaner plunger... with a coat of lanilin.

    And reassembly..

    And loctite on the screws..


    These next two show how the plunger pushes the pinion out to mesh with the ring gear. It meshes then the contacts are made for the motor. it saves alot of wear and damage to the pinion and the ring gear.

    not in mesh


    IN mesh and contacts closed.


    Put the small cover back on, reconnect the motor cable and lanotec everything.

    Chuck it back in the car, reconnect the battery, test start it, reset windows and stereo, .

    I was amazed at how quiet this is now, I heard not a clacking starter motor but a suck or air and the purr of a diesel.
    Fantastic..

    I have more pics at the photobucket page, Some scenes not affecting the outcome were edited out...

    Hope this helps you lot.

    JeffS
    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)

  • #2
    Re: Starter motor rebuild. with lots of pics

    good write up.
    i had the same problem after our last trip.
    did the same and found the contacts were dirty (mud).
    [url=http://www.fuelly.com/driver/damonat/prado][img]http://www.fuelly.com/smallsig-metric/50578.png[/img][/url]

    Comment


    • #3
      Re: Starter motor rebuild. with lots of pics

      Great write up, not something I want to do at this stage but will bee excellent for future reference..
      [color=red]GXL D4D AUTO Option pack more to follow & Camprite TL8s[/color] [url=http://www.fuelly.com/driver/Chuck1/prado][img]http://www.fuelly.com/smallsig-metric/46023.png[/img][/url]

      Diabolus fecit, ut id facerem!

      Comment


      • #4
        Re: Starter motor rebuild. with lots of pics

        Excellent write-up and pics Jeff.

        Sounds like a great idea for our next Tech Day ... now you are the "EXPERIENCED" starter motor reconditioner :lol: :lol: :lol:

        Cheers
        Chippy

        Comment


        • #5
          Re: Starter motor rebuild. with lots of pics

          great write up mate.......my starter motor is on the blink at the moment so will probably be getting a new one in following days...


          joey
          Featured - issue 140 Australian 4wd Action.
          -issue 52 Modified 4wds .
          Locked ,Lifted, boosted Brut---"Pradzilla".
          [IMG]http://i236.photobucket.com/albums/ff268/bigfryy/_0481154045-2.jpg[/IMG]

          Comment


          • #6
            Re: Starter motor rebuild. with lots of pics

            Whats wrong with it joey?


            Jeff.
            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)

            Comment


            • #7
              Re: Starter motor rebuild. with lots of pics

              Thank you for the write up. I had starter problems after LF&R drove my rig through deep water (OK,I did it 9 times and he did it once) the contacts corroded and had to be replaced. I had problems just taking off the starter (4.0L petrol).

              I think this may be above my ability as of now, but every time I read your post I feel more confident I can do it.

              Question; Can the plunger and points be replaced while the started is on the vehicle, or is that just too much for in the bush?

              Thank you,

              -Ben
              "Don't worry about the world coming to an end today. It's already tomorrow in Australia" (Charles Schultz)

              I have a 2007 FJ Cruiser (An American knock-off 120) Considerably built up.

              I am also a Founding Father of the FJ Bruisers, FJ Cruiser club, in Washington D.C.
              Check us out....
              [url]http://www.fjbruisers.com[/url]
              Our discussion forum....
              [url]http://www.fjbruisers.org/forum/[/url]

              [img]http://i78.photobucket.com/albums/j115/hayesy72/logo-1.jpg[/img]

              Comment


              • #8
                Re: Starter motor rebuild. with lots of pics

                Originally posted by FlyNdrive

                Question; Can the plunger and points be replaced while the started is on the vehicle, or is that just too much for in the bush?

                Thank you,

                -Ben

                Hiya Ben.

                If the petrol starter is similar to the diesel one I would have to answer YES, it could be done.
                The small steel cover with 3 small screws is all that needs to be removed. then the spring would come out then the plunger, that would reveal the contacts. That would allow you to possibly get in to clean the contacts enough to get out of trouble. But remember that to outside terminal will be live as it has a direct cable to the battery. Could be a few sparks if you use something metalic to clean it up.

                Note the diesels exhaust pipes exit the other side of the motor. V6 has pipes on both sides..

                Hope it helps ya Ben...
                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)

                Comment


                • #9
                  Re: Starter motor rebuild. with lots of pics

                  this is another one of those threads you need when things go bugger up....

                  after issues with my starter motor, pulled it out today striped it and cleaned it and now works like a champion...

                  thanks to gimp for guiding me through....toyota wanted to charge a grand for a new one....

                  cheers
                  Featured - issue 140 Australian 4wd Action.
                  -issue 52 Modified 4wds .
                  Locked ,Lifted, boosted Brut---"Pradzilla".
                  [IMG]http://i236.photobucket.com/albums/ff268/bigfryy/_0481154045-2.jpg[/IMG]

                  Comment


                  • #10
                    Re: Starter motor rebuild. with lots of pics

                    Thanks Jeff,

                    I had a look under the FJ and it appears accessable. I will add a starter rebuild kit to my parts and scrub the starter. I'm already carrying too much already.

                    -Ben
                    "Don't worry about the world coming to an end today. It's already tomorrow in Australia" (Charles Schultz)

                    I have a 2007 FJ Cruiser (An American knock-off 120) Considerably built up.

                    I am also a Founding Father of the FJ Bruisers, FJ Cruiser club, in Washington D.C.
                    Check us out....
                    [url]http://www.fjbruisers.com[/url]
                    Our discussion forum....
                    [url]http://www.fjbruisers.org/forum/[/url]

                    [img]http://i78.photobucket.com/albums/j115/hayesy72/logo-1.jpg[/img]

                    Comment


                    • #11
                      Re: Starter motor rebuild. with lots of pics

                      G'day folks,

                      Glad a did a serach before starting a new thread subject.

                      Chasing up a few idea how long a starter motor on a v6 4 litre petrol should last ?

                      The boss's just called me and it would appear the solenoid has called it a day - could hear it clicking away merrily whilst he was speaking (polite term) to me on the phone.

                      Any info appreciated, hate to think how much service centre would cost to repair/replace it

                      Cheers

                      Dean
                      2008 GX turbo diesel auto 5sp Fitted: snorkel dual battery kit kaymar twin wheel carrier Evenutally fitted: Bullbar VHF & UHF radios, storage system Still to come: winning lotto number to pay the blessed thing off set of decent side steps/rock sliders

                      Too many projects so little time and even less money

                      Comment


                      • #12
                        Re: Starter motor rebuild. with lots of pics

                        outstanding post jeff,, i'll do mine when the time comes, too easy now ive read your post, top job..... butane
                        [u][i][b][color=#0000FF] ..lets take her out for a spin... butane[/color][/b][/i][/u]

                        [url]http://www.youtube.com/watch?v=BFK707FE9SM[/url]

                        Comment


                        • #13
                          Re: Starter motor rebuild. with lots of pics

                          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)
                          Richard
                          2011 GXL TD Auto Prado Silver

                          Comment


                          • #14
                            Sorry to dig up an old thread but just wanted to give my appreciation for the write up. I'll be tackling this job on the weekend after my starter had a good drink a couple of weeks ago and has progressively gotten worse. I probably wouldn't have even tried pulling it apart myself without this writeup. Thank you!
                            2005 GXL KZJ120 3.0TD. Goodies: 2" TJM XGS Gold Suspension Lift, Safari Snorkel, TJM Underbody Protection, Sovereign Bullbar, AMTS radiator guard, spare wheel spacer & soverign bar LED lights, Runva 11XP Winch, Front Recovery Points, BRC Quad Breathers, Rhino-Rack Pioneer Platform, IPF spotties converted to HID, Drifta Drawers D2D-WT, Autosafe Cargo Barrier, Uniden UHF, 265/70/17 BFG AT's.

                            Comment


                            • #15
                              Might be an oldie, but damn handy

                              Comment

                              canli bahis siteleri bahis siteleri ecebet.net
                              mencisport.com
                              antalya escort
                              tsyd.org deneme bonusu veren siteler
                              deneme bonusu veren siteler
                              gaziantep escort
                              gaziantep escort
                              asyabahis maltcasino olabahis olabahis
                              erotik film izle Rus escort gaziantep rus escort
                              atasehir escort tuzla escort
                              sikis sex hatti
                              en iyi casino siteleri
                              deneme bonusu veren siteler
                              casibom
                              deneme bonusu veren siteler
                              deneme bonusu veren siteler
                              betticket istanbulbahis
                              Working...
                              X