Hello TacticalAnt.
My local
starter motor place couldn’t get the 2.7kW DENSO
starter motor as a replacement unit so I rebuilt mine. They could get a non-OE replacement for ~£140 but I thought it couldn’t be hard to fix up. Mine was temperamental rather than failed.
Toyota quoted me very silly money for a rebuilt one, but I could do that myself. I replaced the two contacts and the plunger. Simples.
I got the parts from Toyota and unlike the boots (other post) these were really good priced. It was a couple of years ago but I think the contacts were ~£6 each and the plunger was ~£15. Seems Toyota sometimes just makes up numbers, no?
There are lots of really good YT videos that show how to replace the
starter contacts. One of the contacts wears much more than the other (due to current). One tightens against the casing and the other doesn’t. The manual recommends using a hardwood block mounted in a press or something similar to hold the hard to tighten one. It’s important that the contacts are flat otherwise they will wear quickly. The third picture is before tightening the RH contact btw.
The white sheet also came with the contact and is there as an insulator.
I was really pleased with the results (part labels covered with adhesive see-through vinyl book cover material then masking tape for the ‘reveal’).
HTH!!