1996 TOYOTA TERCEL clutch

EM9410
1
2 3
45
6
- ENGINE MECHANICALCYLINDER BLOCK
EM-91
1996 TERCEL (RM440U)
(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the mounting bolts, in several
passes, in the sequence shown.
Torque: 90 N´m (900 kgf´cm, 65 ft´lbf)
25. A/T:
INSTALL DRIVE PLATE (See step 24)
26. M/T:
INSTALL CLUTCH DISC AND COVER

ST0N2-01
B11226
End CoverBrush Holder
Rear BearingArmature
Front Bearing
Field Frame (Field Coil)
Startor Housing
Bearing
Idler Gear
Magnetic Switch Assembly
Return Spring
Steel BallClutch Assembly

Terminal C Kit Part
Terminal 30 Kit Part
Terminal Nut
Wave Washer
O-Ring
Terminal Insulater Outer
Contact Plate
Insulation
Paper
Terminal Insulater Inner
Terminal Bolt
Lead Clamp
End Cover
GasketPlungerO-Ring
Wave Washer
Terminal Nut
Terminal Insulater Outer
Terminal Bolt
Lead Terminal
Contact Plate
Terminal Insulater Inner

Non-reusable part ST-2
- STARTINGSTARTER (Reduction Type)
647 Author
: Date
:
1996 TERCEL (RM440U)
STARTER (Reduction Type)
COMPONENTS

ST0IX-01
P25750
P25751
P25783
Cutout
Protrusion
P25753
ST0941
(2)
(4)(3)
(1) ST-4
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove the 2 through bolts.
Torque: 9.3 N´m (95 kgf´cm, 82 in.´lbf)
(c) Pull out the field frame together with the armature.
HINT:
Align the protrusion of the field frame with the grove of the mag-
netic switch.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR
(a) Remove the 2 screws.
Torque: 9.3 N´m (95 kgf´cm, 82 in.´lbf)
(b) Remove these parts from the magnetic switch:
(1) Starter housing
(2) Idler gear and bearing
(3) Clutch assembly
(4) Return spring
HINT:
Insert the return spring in to the magnetic switch hole.

ST0009
Magnet
P25752
ST0198
- STARTINGSTARTER (Reduction Type)
ST-5
1996 TERCEL (RM440U)
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSHES AND BRUSH HOLDER
(a) Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N´m (15 kgf´cm, 13 in.´lbf)
(b) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder. Disconnect the 4
brushes, and remove the brush holder.
NOTICE:
Check that the positive (+) lead wire are not grounded.
5. REMOVE ARMATURE FROM FIELD FRAME

ST0199
Continuity
ST0200
No Continuity
N00337
ST0019
ST0203
Continuity
- STARTINGSTARTER (Reduction Type)
ST-7
1996 TERCEL (RM440U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, replace the field frame.
9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 13.5 mm (0.531 in.)
Minimum length: 8.5 mm (0.334 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is not as specified, replace the brush
springs.
11. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.

P10821
Free
Lock
ST0204
Terminal 50
Continuity
Terminal C
ST0205
Continuity Terminal 50Switch Body ST-8
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
13. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Try to rotate the pinion gear counterclockwise and check that
it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
17. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, check and replace the magnetic switch.

ST0J1-01
P13459
Terminal 50
Terminal C
Battery
P13460
Terminal C
Battery
Disconnect
P13461
Battery
Disconnect
P13462
Battery
Ammeter Terminal 50
Terminal 30
- STARTINGSTARTER (Reduction Type)
ST-13
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO HOLD-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter the
current specified in the respective repair manual.

ST0MW-01
B05050
Magnetic Switch
Drive Level
Plate Washer
PlateStop Collar
Starter Housing
Snap Ring
Starter Clutch
Planetary GearPlate Carrier ShaftIntemal Gear

Non-reusable partSnap Ring
Plate Washer
Center Beaning
Armature Plate Washer

O-Ring Shock Absorber
Field Frame
(Field Coil)
End CoverBrush Holder
O-Ring
- STARTINGSTARTER (Planetary Type)
ST-15
660 Author
: Date
:
1996 TERCEL (RM440U)
STARTER (Planetary Type)
COMPONENTS