Last Modified: 05-08-2025 6.11:8.1.0 Doc ID: RM100000001QKPM
Model Year Start: 2021 Model: RAV4 Prod Date Range: [08/2020 - 12/2021]
Title: A25A-FKS (STARTING): STARTER (w/ Stop And Start System): DISASSEMBLY; 2021 MY RAV4 [08/2020 - 12/2021]

DISASSEMBLY

PROCEDURE

1. REMOVE WIRE HARNESS

(a) Remove the 2 nuts and wire harness from the starter assembly.

*1

Wire Harness

*a

Nut

*b

Noise Filter Harness

(b) Disconnect the noise filter harness from the repair service starter kit.

2. REMOVE STARTER INRUSH CURRENT REDUCTION RELAY

(a) Remove the nut and disconnect the lead wire from terminal M.

*a

Lead Wire

(b) Remove the 2 bolts and starter inrush current reduction relay from the starter drive housing assembly.

3. REMOVE REPAIR SERVICE STARTER KIT

(a) While holding the repair service starter kit to the starter drive housing assembly, remove the 2 nuts.

(b) While lifting the rear of the magnet switch, remove the hook from the pinion drive lever, then remove the repair service starter kit.

NOTICE:

Do not drop the plunger when removing the repair service starter kit.

*1

Pinion Drive Lever

*2

Plunger

*a

Hook

4. REMOVE STARTER YOKE ASSEMBLY

(a) Using a T25 "TORX" socket wrench, remove the 2 through bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly.

*1

Starter Yoke Assembly

*2

Starter Commutator End Frame Assembly

5. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Remove the 2 screws.

*1

Starter Yoke Assembly

*2

Starter Commutator End Frame Assembly

*a

Lead Wire

(b) While holding down the lead wire, remove the starter commutator end frame assembly from the starter yoke assembly.

6. REMOVE STARTER BRUSH HOLDER ASSEMBLY

(a) Using a screwdriver, hold the brush spring back and disconnect the 4 brushes.

*a

Brush Spring

*b

Brush

(b) Remove the starter brush holder assembly from the starter armature assembly.

7. REMOVE STARTER ARMATURE ASSEMBLY

(a) Remove the starter armature assembly from the starter yoke assembly.

*1

Starter Yoke Assembly

*2

Starter Armature Assembly

8. REMOVE STARTER ARMATURE PLATE

(a) Remove the starter armature plate from the starter drive housing assembly or starter yoke assembly.

*1

Starter Yoke Assembly

*2

Starter Drive Housing Assembly

*3

Starter Armature Plate

9. REMOVE PLANETARY GEAR

(a) Remove the 3 planetary gears from the starter center bearing clutch sub-assembly.

10. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) Remove the starter center bearing clutch sub-assembly together with the pinion drive lever and rubber seal from the starter drive housing assembly.

*1

Starter Center Bearing Clutch Sub-assembly

*2

Pinion Drive Lever

*3

Rubber Seal

(b) Remove the pinion drive lever and rubber seal from the starter center bearing clutch sub-assembly.