Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA1995T100 DX, RWD, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALSTARTERSTARTING SYSTEMBENCH TESTINGSTARTER COMPONENT INSPECTIONCOMMUTATOR
1995 Toyota T100 DX, RWD, Standard
Starter Component Inspection: Commutator
1995 Toyota T100 DX, RWD, StandardSECTION Commutator
- If commutator surface is dirty or burnt, it can be cleaned with No. 400 grit sandpaper or on a lathe. If commutator runout (out-of-round) is more than .002" (.05 mm), turn commutator on a lathe. Wear or cutting limit of commutator diameter is 1.06" (27 mm) for 0.8 kW starter, 1.14" (29.0 mm) for 1.0, 1.2, 1.4, 1.6 and 1.8 kW starter, and 1.34" (34 mm) for 2.0 kW starter. If commutator diameter is less than minimum, replace armature.
- Ensure undercut depth between commutator segments are clean, free of debris, and that edges are smooth. Minimum undercut depth is .008" (.20 mm). If undercut depth is less than minimum, use a hacksaw blade to correct to a depth of .008-.024" (.20-.60 mm).
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.