Toyota Tundra (2015 year). Manual — part 1806
(1) Disconnect the negative (-) lead from the starter body.
Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return inward, replace
the magnet starter switch assembly.
(d) Perform an operation test without load.
(1) Connect the field coil lead wire to terminal C with the nut.
Torque:
10 N·m {102 kgf·cm, 7ft·lbf}
(2) Mount the starter in a vise between aluminum plates.
(3) Connect the battery and an ammeter to the starter as
shown in the illustration.
(4) 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 MAGNET STARTER SWITCH ASSEMBLY
(a) Check if the pull-in coil has an open circuit.
(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
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starter switch assembly.
(b) Check if the holding coil has an open circuit.
(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.
3. INSPECT STARTER ARMATURE ASSEMBLY
If necessary, replace the starter armature assembly.
(b) Measure the resistance.
(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.
(2) 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.
(c) Check the commutator circle runout.
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(1) Place the armature shaft on V-blocks.
(2) Using a dial indicator, measure the circle runout.
Maximum runout:
0.05 mm (0.00197 in.)
If the circle runout is more than the maximum, 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.
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, increase the
depth using a hacksaw blade.
4. 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 length is less than the minimum, replace the starter
brush holder assembly.
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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.
5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
check that it turns freely. Try to rotate the pinion gear
counterclockwise and check that it locks.
If the result is not as specified, replace the starter center
bearing clutch sub-assembly.
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