Toyota Tundra Service Manual: Inspection

INSPECTION

PROCEDURE

1. INSPECT STARTER ASSEMBLY

CAUTION:

As a large electric current passes through the cable during this inspection, a thick cable must be used.

Otherwise, the cable may become hot and cause injury.

NOTICE:

These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

(a) Mount the starter in a vise between aluminum plates.

(b) Perform a pull-in test.

(1) Remove the nut and disconnect the field coil wire from terminal C.

(2) Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.

If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.

(c) Perform a holding test.

(1) Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.

If the clutch pinion gear moves inward, replace the magnet starter switch assembly.

(d) Inspect clutch pinion gear return.

(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.

If the clutch pinion gear does not move inward, replace the magnet starter switch assembly.

(e) Perform an operation test without load.

(1) Connect the field coil wire to terminal C with the nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(2) Connect the battery and an ammeter to the starter as shown in the illustration.

(3) Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

Standard current:

150 A or less at 11.5 V

If the result is not as specified, replace the starter assembly.

2. INSPECT STARTER ARMATURE ASSEMBLY

(a) Check the surface of the commutator for dirt and burns.

If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

If necessary, replace the starter armature assembly.

(b) Inspect the commutator for an open circuit.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

Segment - Segment

Always

Below 1 Ω

If the result is not as specified, replace the starter armature assembly.

(c) Inspect the commutator for a short circuit.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

Segment - Coil core

Always

10 kΩ or higher

If the result is not as specified, replace the starter armature assembly.

(d) Using a vernier caliper, measure the commutator diameter.

Standard diameter:

29.0 mm (1.14 in.)

Minimum diameter:

28.0 mm (1.10 in.)

HINT:

Be sure to measure the commutator diameter at the ridges.

If the diameter is less than the minimum, replace the starter armature assembly.

(e) Check the commutator runout.

(1) Place the armature shaft on V-blocks.

(2) Using a dial indicator, measure the circle runout.

Maximum commutator runout:

0.05 mm (0.00197 in.)

If the commutator runout is more than the maximum, replace the starter armature assembly.

(f) Using a vernier caliper, measure the undercut depth of the commutator.

Standard undercut depth:

0.4 mm (0.0157 in.)

Minimum undercut depth:

0.2 mm (0.00787 in.)

HINT:

Be sure to measure the commutator undercut depth at a cutout.

If the undercut depth is less than the minimum, correct it with a hacksaw blade.

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

(a) Using a vernier caliper, measure the brush length.

Standard length:

14.4 mm (0.567 in.)

Minimum length:

9.0 mm (0.354 in.)

HINT:

Be sure to measure the brush lengths at the protrusions.

If the brush length is less than the minimum, replace the starter brush holder assembly.

(b) Inspect the load of the brush spring.

(1) Take a pull scale reading immediately after the brush spring separates from the brush.

Standard spring load:

22 to 27 N (2 to 3 kgf, 5.0 to 6.1 lbf)

Minimum spring load:

14 N (1 kgf, 3.1 lbf)

If the load is less than the minimum, replace the starter brush holder assembly.

4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) Check the gear teeth of the planetary gears and starter center bearing clutch for wear or damage.

If any planetary gear is damaged, replace the planetary gear assembly. If any teeth of the starter center bearing clutch are damaged, replace the starter center bearing clutch sub-assembly.

(b) Check the movement of the clutch pinion gear.

(1) Rotate the clutch pinion gear clockwise, and check that it turns freely.

(2) Try to rotate the clutch pinion gear counterclockwise, and check that it locks.

If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

5. INSPECT MAGNET STARTER SWITCH ASSEMBLY

(a) Inspect the pull-in coil.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

Terminal 50 - Terminal C

Always

Below 1 Ω

If the result is not as specified, replace the magnet starter switch assembly.

(b) Inspect the holding coil.

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

Terminal 50 - Switch body

Always

Below 2 Ω

If the result is not as specified, replace the magnet starter switch assembly.

    Disassembly

    Installation

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