Starter removal, repair. - Page 6 - Toyota FJ Cruiser Forum
Engine Performance This forum is for discussion on gas, oil, exhaust and all things engine related.

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post #51 of 61 (permalink) Old 05-20-2017, 01:58 AM
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Re: Starter removal, repair.

So I found the correct contact parts and while trying to take off the bottom 14mm bolt it rounded off like a hot knife through butter!



Gotta pick up a bolt extractor kit tomorrow and try again. In my case I will have to pull the starter through the top since I have the Icon S2 system in the way.


2015 Camry SE
2012 Porsche Cayenne
2008 FJ Cruiser
2003 Camry LE (RIP)
2000 Mazda Miata
1997 Camao Z28 383ci supercharged

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post #52 of 61 (permalink) Old 06-07-2018, 02:43 PM
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Re: Starter removal, repair.

Old thread post but this seemed like the best place to share the information.

I found a source for the Denso starter rebuild parts for the 07-08 starters. These may fit the other models but I do not know for sure.

Source: https://www.aspwholesale.com/starter...er-p10016.html

Thats the whole brand new starter but if you click on the Parts List tab below the picture of the starter you will find that they list an entire rebuild kit as well as all the individual parts and part numbers.

If all you want is the contacts and some of the other small parts then the indiviual parts are probably the way to go. They do require a $10 minimum to ship so keep that in mind.

Here are the two contacts:
Part Number 66-82756 ($0.72) https://www.aspwholesale.com/contact-nd-p6980.html
Part Number 66-82780 ($1.29) https://www.aspwholesale.com/contact-nd-p8800.html

The plunger pn# listed in the rebuild kit (66-82609) doesnt appear to be available from ASP. I believe I may have found the correct one listed under a different pn# as it is listed for Denso OSGR 2.0kW starter and the OAL is very similar. I am not 100% sure that what I found is the correct plunger but it appears to be very close. Only thing I am not sure of is if the width of the plunger contact is the same. This one is listed at 34.8mm wide but I dont know how wide the OEM one is. Maybe someone will see this and measure the width at the contact ring?

Here is a soucre that lists the same plunger pn# (66-82609) as the rebuild kit and details including a 97mm OAL but they dont sell to the public.

This plunger is listed by ASP as fitting the Denso OSGR 2.0kW starter and is 96.7mm OAL with 34.8mm diameter
https://www.aspwholesale.com/plunger-nd-p5861.html

The complete Denso rebuilt kit is linked here: https://www.aspwholesale.com/starter...it-p13358.html
The parts list for the kit is detailed on the specifications tab under the picture of the starter and appears to be very comprehensive.

For historical sake, here are the parts list and Denso part numbers for the 07-08 starter rebuilt kit

1, 6-102-4 ~ BALL BEARING, ARMATURE
2, 6-104-4W ~ BALL BEARING, DRIVE
1, 62-82801 ~ BUSHING, DRIVE
1, 6-638-4W ~ BALL BEARING, ARMATURE
1, 66-82350 ~ SOLENOID TERMINAL
1, 66-82352 ~ SOLENOID TERMINAL
1, 66-82410 ~ GASKET, SOLENOID COVER
1, 66-82550 ~ SPRING, PLUNGER
1, 66-82609 ~ PLUNGER
1, 66-82756 ~ CONTACT, SOLENOID
1, 66-82780 ~ CONTACT, SOLENOID
2, 68-8225 ~ BRUSH, GROUND
2, 68-8226 ~ BRUSH, FIELD
1, 71-82301 ~ BOOT, MOTOR LEAD
1, 71-82307 ~ GROMMET, MOTOR LEAD
1, 71-82312 ~ DRAIN TUBE
1, 71-82317 ~ DRAIN TUBE
2, 71-82507 ~ O-RING, BR HLDR SCREW
2, 71-82510 ~ O-RING, FIELD CASE
2, 71-82512 ~ O-RING, SOL TERM POSTS
1, 72-82400 ~ INSULATOR, SOL TERM (EXT.)
2, 72-82409 ~ INSULATOR, SOL TERM (INT.)
1, 72-82415 ~ INSULATOR, SOL TERM (EXT.)
1, 76-82802 ~ STEEL BALL, SOLENOID PLUNGER
1, 76-82806 ~ RETAINER RING, DRIVE
1, 76-82807 ~ STOP COLLAR
2, 85-2402 ~ HEX NUT, SOLENOID TERMINAL
2, 85-4504 ~ CONICAL WASHER, SOLENOID TERMINAL
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Last edited by ROMAD; 06-08-2018 at 05:20 PM.
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post #53 of 61 (permalink) Old 04-21-2019, 08:05 PM
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Re: Starter removal, repair.

Thread resurrection.

I have a 2012 FJ. I have followed all the instructions on this forum in an effort to remove the starter. Looked at the couple of Youtube videos about the subject. I have the starter completely disconnected. However I cannot figure out the tetris required to actually remove the started from the vehicle.

I have rotated, twisted and fiddled with it to get it in a position compatible for removal. I do not see a method I can get it out without either removing the exhaust manifold or the steering column.

Does anyone have some advice for me on this?

Here are a couple of photos that show my plight:
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Last edited by Gryff; 04-21-2019 at 08:07 PM.
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post #54 of 61 (permalink) Old 04-22-2019, 10:57 AM
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Re: Starter removal, repair.

You can fish out the starter via the top by loosing that 10mm bolt that holds down the brake line tee.

-B

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Gryff previously said: View Post
Thread resurrection.

I have a 2012 FJ. I have followed all the instructions on this forum in an effort to remove the starter. Looked at the couple of Youtube videos about the subject. I have the starter completely disconnected. However I cannot figure out the tetris required to actually remove the started from the vehicle.

I have rotated, twisted and fiddled with it to get it in a position compatible for removal. I do not see a method I can get it out without either removing the exhaust manifold or the steering column.

Does anyone have some advice for me on this?

Here are a couple of photos that show my plight:

2015 Camry SE
2012 Porsche Cayenne
2008 FJ Cruiser
2003 Camry LE (RIP)
2000 Mazda Miata
1997 Camao Z28 383ci supercharged
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post #55 of 61 (permalink) Old 04-22-2019, 12:01 PM
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Re: Starter removal, repair.

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Blown383 previously said: View Post
You can fish out the starter via the top by loosing that 10mm bolt that holds down the brake line tee.

-B
Thanks for the tip.

I have all the brake line mounts loose; on top and in the wheel well. The location of that is where it happened to be when I took the photo (no bolt head visible in the photo). There simply does not appear to be enough room between the steering column and the upper control arm mount to come out the side.

Right now it looks like I need to take the exhaust manifold out to get the starter past that. I'm hoping someone can tell me that they've done this successfully on a 2012 without removing the exhaust manifold or upper control arm.
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post #56 of 61 (permalink) Old 04-22-2019, 12:24 PM
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Oh!! I missed that part! If you have to drop the upper control arm it’s pretty easy. Just remove the battery and pull the long bolt out towards the front end of the car. It’s been a while since I’ve done the starter so my memory is a bit fuzzy.

-B

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Quote:
Blown383 previously said: View Post
You can fish out the starter via the top by loosing that 10mm bolt that holds down the brake line tee.

-B
Thanks for the tip.

I have all the brake line mounts loose; on top and in the wheel well. The location of that is where it happened to be when I took the photo (no bolt head visible in the photo). There simply does not appear to be enough room between the steering column and the upper control arm mount to come out the side.

Right now it looks like I need to take the exhaust manifold out to get the starter past that. I'm hoping someone can tell me that they've done this successfully on a 2012 without removing the exhaust manifold or upper control arm.

2015 Camry SE
2012 Porsche Cayenne
2008 FJ Cruiser
2003 Camry LE (RIP)
2000 Mazda Miata
1997 Camao Z28 383ci supercharged
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post #57 of 61 (permalink) Old 04-22-2019, 03:32 PM
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Re: Starter removal, repair.

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Blown383 previously said: View Post
Oh!! I missed that part! If you have to drop the upper control arm itís pretty easy. Just remove the battery and pull the long bolt out towards the front end of the car. Itís been a while since Iíve done the starter so my memory is a bit fuzzy.

-B
I used to do a lot of work on my '67 truck many years ago and I'm confident with a wrench. I know what I'm in for with the manifold. However I have never had to do any fancy suspension work like the front is on this vehicle.

Which do you think is easier: Control arm or manifold?

-Gryf
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post #58 of 61 (permalink) Old 04-22-2019, 03:41 PM
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Re: Starter removal, repair.

Control arm by far is WAAAAY easier and you have ZERO chances of snapping a stud or coming across seized nuts like you would on the manifold. Plus if you yanked the manifold you'll need new gaskets to replace the old one.

-B

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Gryff previously said: View Post
I used to do a lot of work on my '67 truck many years ago and I'm confident with a wrench. I know what I'm in for with the manifold. However I have never had to do any fancy suspension work like the front is on this vehicle.

Which do you think is easier: Control arm or manifold?

-Gryf
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2015 Camry SE
2012 Porsche Cayenne
2008 FJ Cruiser
2003 Camry LE (RIP)
2000 Mazda Miata
1997 Camao Z28 383ci supercharged
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post #59 of 61 (permalink) Old 04-22-2019, 04:06 PM
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Re: Starter removal, repair.

B-383 -

Back in Post #51 you mentioned that you found all the component parts required to rebuild the solenoid section of the starter (both contacts, plunger, contact bolt insulators, etc.).

However, you never mentioned the supplier.

Care to share the source? Granted, it was two years ago ...

Also, what was the final solution to the "rounded bolt head" problem?
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post #60 of 61 (permalink) Old 04-23-2019, 08:26 AM
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Re: Starter removal, repair.

I purchased the rebuild kit from https://leeautoelectric.com/ and if I recall correctly it was about $20 shipped. Just give them a call or email them for the correct part number.

As for removing the stubborn 14mm bolt I highly suggest hitting it with some PB blaster and using a 6 point socket with a breaker bar to bust it loose. Once my bolt started to round off I had to use a bolt extractor and made the mistake of using one of those bolt extractors that supposedly bite into the rounded bolt head as you tightened it. What it did was completely shave off the edges of the bolt. So I ended up using the Lisle 19250 bolt extractor that had to be hammered on. That gave a firm bite on the head and I was able to take it off with a long-handled ratchet and a long pipe. It was a royal pain in the ass!

Here's the offending bolt:


The bolt extractor I used


What the bolt looked like after I beat the extractor on with a small sledgehammer


and how the extractor fit over the rounded off bolt head.


Hopefully, that helps!


-B



Quote:
FJtest previously said: View Post
B-383 -

Back in Post #51 you mentioned that you found all the component parts required to rebuild the solenoid section of the starter (both contacts, plunger, contact bolt insulators, etc.).

However, you never mentioned the supplier.

Care to share the source? Granted, it was two years ago ...

Also, what was the final solution to the "rounded bolt head" problem?

2015 Camry SE
2012 Porsche Cayenne
2008 FJ Cruiser
2003 Camry LE (RIP)
2000 Mazda Miata
1997 Camao Z28 383ci supercharged

Last edited by Blown383; 04-23-2019 at 08:29 AM.
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