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
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
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