Antenna Motor Commutator Repair

[rubad]

Attempting to replace my antenna motor commutator. But in the process see some dangling winding wire so now might have to do some re wounding. Maybe someone have done this and could chime it.

Option on antenna motor?
1. Import a new one for upper 400$
2. Send motor to be rebuild, at least 150$
3. Either buy a used one for around 250$
4. Aftermarket power antenna 30-50$

Because I want to keep original and don't want to pretty much new so don't have have to do it again in the future. Option 1 or 2 is the only way or fix it your self. So decided to fix it myself and get the learning experience.

Tool needed:
Loaner tool from Advance Auto/Autozone
Bearing Separator
Steering Wheel puller

Parts:
Commutator TP1007 from China
US $1.35 |1PC 8 x 15.25 x 14.7mm 10P Copper Bars Hook Type Motor Commutator TP1007-in Tool Parts from Tools on Aliexpress.com | Alibaba Group
$1.35

Here is my original worn down commutator:

Comparison between China vs Original commutator:

Using the tool to extract oldy commutator (pulling the commutator was pretty easy by hand):

Rotor in housing without commutator:

Rotor in housing with china commutator (I was thinking that I have to trim down the commutator but from the looks of it, it will be a nice fit):

 

[rubad]

Also, Chinese commutator fit but not tight so probably good idea to apply epoxy to glue to the shaft.

Dangling wire

So now I guess either someone can chime in on the wire or I just have to get some winding wire to re wound it. Any chance someone know the gauge of the wire. I was thinking following this youtube to do it.

Update: measuring wire seem it is between .37 - .38 mm, so that would be a 28 AWG winding wire

 

[rubad]

Finally got her done and tested straight on using 12V battery and works good. Here my final process on re-winding the power antenna motor.

Additional Parts to re-winding power antenna motor
1 - 2 x 28AWG Winding wire (you will use about 20 gram of winding wire).

I bought 1 lb winding wire but it is way too much. 1 oz should suffice but Amazon only sell in 4 oz minimum.
NTECHGO 28 AWG Magnet Wire - Enameled Copper Wire - Enameled Magnet Winding Wire - 1.0 lb - 0.0122" Diameter 1 Spool Coil Red Temperature Rating 155℃ Widely Used for Transformers Inductors
Amazon product ASIN B07DYJGGMD
2 - Nail Polish - Used it to re-sheath the winding wire in case of mistakes.

- JB Weld stator to shaft

Using 1st winding wire - Pick a stator bar to start
1. remove sheathing just enough to tie it to the bar
2. Loop it 37 times (using same count as original motor) using the 1st winding wire
3. At then end, loop it around the shaft to get ready for the next section but stop here and go to 2nd winding wire.

Using 2nd winding wire - start at 180 degree to the 1 st winding wire starting point
1. Remove sheathing just enough to tie it to the bar
2. Loop it 37 times (using same count as original motor) using the 2nd winding wire
3. At then end, loop it around the shaft to get ready for the next section but stop here and go to 1st winding wire.

Continue switching between 1st and 2nd winding wire until 2nd winding wire reaches 1st winding wire starting point and 1st winding wire reaches 2nd winding wire starting point.

Note: in case you make mistake in removing the winding wire sheathing use nail polish to re-sheath the winding wire.

1st winding and ready for next winding for 1st winding wire

Looping through the shaft for 1st winding

Completed rotor winding

Rebuild rotor in housing to check for clearance

Once your are done with winding the wire here is how you check your work to make sure everything is in order.

Between 180 degree bar - 22 Ohm +/- .1 Ohm
Between adjacent bar - 10 Ohm +/- .1 Ohm

 

[thelal]

great detail

 

[EvanD]

Man, that seems like a lot of work to have a working antenna but I'd that's the goal def seems cost effective.

Thanks for the great write up!

 

[shocktower]

Wow I would have just hunted a Camry or 4runner one that is a lot of work

 

[rubad]

Wow I would have just hunted a Camry or 4runner one that is a lot of work

I didn't know that Camry or 4runner have the same motor spec. Do you know the detail e.g. year? Just wanted to know for future reference.

 

[shocktower]

I didn't know that Camry or 4runner have the same motor spec. Do you know the detail e.g. year? Just wanted to know for future reference.

I will try to search this out, but I know that several things are used in several Toyota's

 

[BrianNOLA]

Reviving an old thread. Same situation here. The commutator wore to the point that the copper was peeling off. Before I start on duplicating Rubad's efforts, has anyone figured out if later year and other model Toyotas have the same antenna as the '97 80 series? I believe this version antenna was only used in the '96 and '97's. It has two electrical connections, one for power and one for a feedback switch, as well as the coaxial cable for the RF signal.