96 Toyota Tacoma 2.7 Starter Rebuild

    Be sure to check the conections to the starter and battery cables before assuming the contacts are bad.

    First off before ever working on the starter be sure to disconnect the battery and place the cables securely away from the posts so they not come in contact with the posts and short anything out.

    I've been told that the procedures are similar, if not the same for all years & engines of Tacomas.

   Part numbers and prices complements of www.TRDParts4U.com. Prices and or part numbers are subject to change with out notice, please contact info@trdparts4u.com to verify. Prices do not include shipping. Be sure to inquire about your TTORA membership discount to receive these discounts.

2.7L (1.4kw) starter P/N: 28100-0C010-84 (reman, not cold spec, $179.95 plus $30 core)
2.7L (1.8kw) starter P/N: 28100-75140-84 (reman, cold spec, $164.74 plus $30 core)

1. Contact P/N: 28226-74070 ($8.22)
2. Contact P/N: 28226-54340 (w/o cold spec $4.37)
    Contact P/N: 28226-22050 (w cold spec $5.81)
3. Plunger P/N: 28235-54380 ($16.65)
4. Clutch (optional, if needed) P/N: 28011-26042 ($58.14)

3.4L (1.4kw) starter P/N: 28100-07010-84 (reman, not cold spec, $168.05 plus $30 core) *Regular cab & Extra Cab may be cold spec or not cold spec
3.4L (1.8kw) starter P/N: 28100-62030-84 (reman, cold spec, $151.32 plus $30 core) *All Double Cabs have cold spec

1. Contact P/N: 28226-74070 ($8.22)
2. Contact P/N: 28226-16130 (not cold spec, $8.22)
    Contact P/N: 28226-54340 (cold spec, $4.37)
3. Plunger P/N: 28235-55050 (not cold spec) 28235-54380 (cold spec) both $16.65
4. Clutch (optional, if needed) P/N: 28011-26042 ($58.14)

I was having the notorious clicking problem on my 96 and got a wild hair instead of buying a reman or Toyota starter I thought I would rebuild mine. To the left or the contacts that wear out inside of the bendix that cause the clicking. Mine wore unevenly I am not sure if this is common or not though.
The Toyota Factory Service Manual ( FSM Starter files ) stated maximum wear: 0.9 mm ( 0.035in. ). If the depth of wear is greater than the maximum, replace the contact plate.

   To the right are the replacement parts (not including the plunger). I didn't initially order a plunger though when I ordered the contact kit. Remember, if you order a starter rebuild kit the plunger is sold separately, and is not considered part of a contact rebuild. However, if you are going this far into the starter it's a good idea to replace it as well because they are usually scored and will wear out the new contacts faster.

This is the rear of the starter the three bolts in the triangular pattern at the top need to be removed to reveal the inside of the bendix where the contacts are. The FSM recommends replacing the gasket.

   There is a plunger in here that just slides out. It will push upwards a little as it has a rod that goes into the spring seen in the picture.

    This is the plunger I didn't get. The picture quality isn't real good but you can make out that it is gaulded. At the recommendation from another member that you can use a wire brush to clean the plunger up.

    These are the parts from the right side ( looking at the back of starter with the bendix up, also known as terminal C from the FSM ) where the bendix and starter wire together.I layed them out in the order they came out.

    This is the left side ( also known as terminal 30 in the FSM ). This stud connects to the hot wire from the battery that was unhooked to remove the starter.

Here is some torque info from the 96 FSM. You can also find links to some of the FSM files .

Torque for the terminal 30 is 17 N-m ( 173 kgf-cm, 13 ft-lbf )
Note: over tightening may cause cracks on the inside insulator. Also note to place the inside insulator in correctly.

End cover bolts torque:

2.5 N-m ( 25 kgf-cm, 22 in-lbf ) for 1.4 kW

3.6N-m ( 37 kgf-cm, 32 in-lbf ) for 2.0 kW

This is how I got the starter out. I had to bend the brake line slightly and turn the starter and wiggle but it looked much easier than the alternatives. Be extremely careful when bending break lines as they are easily kinked.

Contact www.trdparts4u.com threw one of the following methods.
www.toyotapartsales.com
info@toyotapartsales.com
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info@trdparts4u.com
Call 800.442.4349 and talk to: Barb, Brian, Kasey, John, Stephanie or Raul

This article is for informational purposes only. Any repair, especially involving the electrical system, incurs the potential for vehicle damage and/or serious injury or death. I have performed the following repair based on my understanding of the risks and procedures involved. I, or anyone named in this article, assume no responsibility for any damage, injury or death for any mishap arising out of the use of this article to perform maintenance or repair. Maintenance and repairs should be performed by properly trained technicians.