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2002 GC Starter & Top Bolt Question

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Old Sep 19, 2011 | 03:24 PM
  #11  
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greaper_ca
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Originally Posted by 2therock
The Starter Removal, Contact Replacement and Installation was a great success! Thanks guys! $10.00 Vs. $80.00. Mercy Louella!
Thanks Tizzy 1 for the manual picture info.
Thanks 22mopar22 http://www.4crawler.com for the fabulous Webb site instructions and the fast order precessing of the contacts I ordered.

My 2002 Grand Caravan Sport used the A & B contacts in the set ordered from 4crawler. I think the multiple part numbers are all the same part but for different vehicles so if one is out of stock ask for the other. Or order from 4Crawler.
A: Toyota p/n 28226-72010, 28226-72080, 28226-74040.
B: Toyota p/n 28226-72040, 28226-22050.

I pulled the starter and changed the contacts and put her back in and she is good to go.

Starter Change notes for a 2002 Grand Caravan:

As per usual disconnect the negative battery wire.
Disconnect the wires from the starter.

  • Do the Top bolt 1st so the starter can walk out when you do the bottom bolt. The top starter bolt can be done from above.
  • There are two ground wires on the top starter bolt. A medium 3/8 drive extension and deep well 13mm removes that nut.
  • Change to a 15mm and remove the top bolt.
  • The bottom bolt is accessed from the bottom. I used a flex-head long handled 3/8 drive ratchet (on top and bottom bolts) and a regular 15mm socket to remove it.
  • When you are backing out the bottom bolt the ratchet will move out and hit something so you need to push the starter out as you loosen the bolt.
  • I cleaned the starter with Simple Green and removed the solenoid cover.
  • I did one contact at a time.
  • The battery wire contact is simple and take care on both to keep track of what you are doing so you can reverse it. When you tighten the contacts make sure you do not let them rotate to an out of level position. There was a paper shim or gasket on my battery wire side.
  • The other side has a very small wire coming out of the motor terminating at the bolt so take care not to break it. If that wire breaks you are headed to the parts store with $80.00.
  • I used a very small tack hammer to gently rap on it to loosen everything off the bolt so I could easily pull it out through spade connector with minimal flexing of the wire.
  • I used a very fine stiff wire brush to clean the plunger disc. It was pitted and worn but will last another 100k.
  • Assembly. The metal shim that goes between the starter and the motor will give you a fit so be patient and slide it all in taking care to know you have it all lined up. You will need a light so you can peek in and see the dowel pin go into the hole and keep an eye on the shim plate.
  • Work the lower bolt in and get it a little tighter than hand tight and move to the top. Tighten the top but not with the wires yet.
  • Then tighten the bottom and check the top again and re-fasten the wires.
  • Connect the battery and Test.
The old contacts pictured below with the Battery side being the most worn.
Hey Rock...how easy was it for you to take out the starter? From reading your post, is the 15mm bolt hidden behind the connector wire? I took out the nut and the bottom bolt, but couldn't take out the starter. If it's hidden behind the wire, then that would explain why I can't take out the starter. At the moment, it's raining right now and I don't have a garage to work in so I'll have to check later, unless you guys can answer this right away.

Thanks.
 
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Old Sep 19, 2011 | 03:32 PM
  #12  
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greaper_ca
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No need to answer this question. Found the answer from another thread. It is hidden! So now I just have to wait for a day when it's not raining and some time to take that bugger out.

Thanks again.
 
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