Attention: TDR Forum Junkies 
My 2007, 5.9 has the later style Denso starter. It does not have the easily rebuildable solenoid like the earlier Denso starters. This same starter has carried through to the 6.7 engine. Truck has always started well. One MAJOR Thing that I see guys doing that is very hard on starters AND alternators is running their Batteries to the bitter end. As cranking voltages drop, AMP draw across the starter AND the solenoid contacts increases to make up for the low battery voltage. I ran a set of Sears Platinums and now have a set of Odyssey's, 950 cca amp with 1750 ca hot for 5 seconds. The starter sounds like it is on 24 volts!
So, the starter sounded a little dry while cranking and when the key was let go. My truck is a standard trans.
These starters are a 3 gear planetary gear reduction type starter which is different from the earlier Denso starters 2006 and down.
I easily pulled the starter although it is heavy. I benched it and pulled the small screws first pff of the back cover of the starter. This releases the starter brush plate from the cover. Removed the cover and very surprising, there wasn't a lot of brush "crumbs" inside. The main field can now be removed but be careful with the brushes to not damage them. The armature is now exposed and can be removed from the 3 gear planetary. My commutator while dirty cleaned up very quickly on my lathe with abrasive paper. I scraped out the grooves between the segments and re polished it. I cleaned the planetary with solvent then scrubbed with Purple Power detergent to remove all solvents so new grease will stick. I chose to use a LIGHT weight Moly grease as it is a very high pressure grease.
The main drive that engages into the starter ring or flywheel is a bear to get out. The ring at the end has to be pushed down and then the ring removed. You can remove the starter pinion. There are a couple of bolts that will remove the very front of the starter nose cone. You can unhook the drive from the solenoid fork and get to the MAIN bushing for the starter pinion drive shaft. I removed the pinion drive shaft, cleaned out the bushing and re-lubed it with Moly grease. The ball bearing needed to be cleaned and repacked. I reinstalled the front nose cone. Installing the pinion again and getting the clip in place took MUCH patience and you really need THREE hands. I lubed up the planetaries liberally but didn't over do it, lubed the bearing at the front of the planetaries where the armature with the gear on it fits. The back bearing on the armature is a sealed bearing. CAREFULLY peal the seal from the OUTER side of the seal and wipe out the bearing, repack it with Moly grease and push the seal back in place. I slid the center section back on with the field coils and reconnected it to the solenoid. To get the brushed back in place over the commutator takes some doing but it is easy if you have done it before. FIRST, CLEAN your hands of ANY grease. You want the commutator and brush faces spotless with NO grease on them. With your fingers, a hook tool to pull the wire braid or a soft piece of wood to be used on the brush contact side out, move the brushes carefully out enough to where the spring that pushes on the brush pushes on the SIDE of the brush because it was pushed up far enough. Do this to all four. Now you can install the brush plate over the end of the armature shaft and then release each brush down into their holders. assemble back together the end of the starter motor and replace the little screws that hold the brush plate. Bench test the starter before replacement.
My starter is now quieter and spins FAST! I am going to check with Larry B's about replacement solenoids.
So, the starter sounded a little dry while cranking and when the key was let go. My truck is a standard trans.
These starters are a 3 gear planetary gear reduction type starter which is different from the earlier Denso starters 2006 and down.
I easily pulled the starter although it is heavy. I benched it and pulled the small screws first pff of the back cover of the starter. This releases the starter brush plate from the cover. Removed the cover and very surprising, there wasn't a lot of brush "crumbs" inside. The main field can now be removed but be careful with the brushes to not damage them. The armature is now exposed and can be removed from the 3 gear planetary. My commutator while dirty cleaned up very quickly on my lathe with abrasive paper. I scraped out the grooves between the segments and re polished it. I cleaned the planetary with solvent then scrubbed with Purple Power detergent to remove all solvents so new grease will stick. I chose to use a LIGHT weight Moly grease as it is a very high pressure grease.
The main drive that engages into the starter ring or flywheel is a bear to get out. The ring at the end has to be pushed down and then the ring removed. You can remove the starter pinion. There are a couple of bolts that will remove the very front of the starter nose cone. You can unhook the drive from the solenoid fork and get to the MAIN bushing for the starter pinion drive shaft. I removed the pinion drive shaft, cleaned out the bushing and re-lubed it with Moly grease. The ball bearing needed to be cleaned and repacked. I reinstalled the front nose cone. Installing the pinion again and getting the clip in place took MUCH patience and you really need THREE hands. I lubed up the planetaries liberally but didn't over do it, lubed the bearing at the front of the planetaries where the armature with the gear on it fits. The back bearing on the armature is a sealed bearing. CAREFULLY peal the seal from the OUTER side of the seal and wipe out the bearing, repack it with Moly grease and push the seal back in place. I slid the center section back on with the field coils and reconnected it to the solenoid. To get the brushed back in place over the commutator takes some doing but it is easy if you have done it before. FIRST, CLEAN your hands of ANY grease. You want the commutator and brush faces spotless with NO grease on them. With your fingers, a hook tool to pull the wire braid or a soft piece of wood to be used on the brush contact side out, move the brushes carefully out enough to where the spring that pushes on the brush pushes on the SIDE of the brush because it was pushed up far enough. Do this to all four. Now you can install the brush plate over the end of the armature shaft and then release each brush down into their holders. assemble back together the end of the starter motor and replace the little screws that hold the brush plate. Bench test the starter before replacement.
My starter is now quieter and spins FAST! I am going to check with Larry B's about replacement solenoids.
