Starter Disassembly

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
1Gr-Fe Starting. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. REMOVE REPAIR SERVICE STARTER KIT

  2. REMOVE STARTER YOKE ASSEMBLY

  3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY

  4. REMOVE STARTER ARMATURE PLATE

  5. REMOVE STARTER COMMUTATOR END FRAME COVER

  6. REMOVE STARTER ARMATURE ASSEMBLY

  7. REMOVE PLANETARY GEAR

  8. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

Starter -- Disassembly



1. REMOVE REPAIR SERVICE STARTER KIT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the nut and disconnect the lead wire from terminal C.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 2 screws holding the repair service starter kit to the starter drive housing.

  1. Remove the repair service starter kit.

  1. Remove the return spring and plunger from the starter drive housing.



2. REMOVE STARTER YOKE ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 2 through bolts and pull out the starter yoke together with the starter commutator end frame.



3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the starter commutator end frame from the starter yoke.



4. REMOVE STARTER ARMATURE PLATE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the starter armature plate from the starter yoke.



5. REMOVE STARTER COMMUTATOR END FRAME COVER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Using a screwdriver, remove the starter commutator end frame cover.



6. REMOVE STARTER ARMATURE ASSEMBLY
NOTICE:
Do not drop the starter armature.
  1. Mount the starter commutator end frame in a vise between aluminum plates.

    NOTICE:
    Do not damage the starter commutator end frame.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Using snap ring pliers, remove the snap ring and plate washer.

    NOTICE:
    Do not drop the starter armature.
  1. Remove the starter armature from the starter commutator end frame.



7. REMOVE PLANETARY GEAR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the 3 planetary gears from the starter center bearing clutch.



8. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
  1. Remove the starter center bearing clutch and drive lever set pin from the starter drive housing.

  1. Remove the drive lever set pin from the starter center bearing clutch.