possum yota

i just recently bought a 91 4x4 the motor was rebuilt before i bought it. when i turn the key it clicks but no starter response. also tried jumping truck off but the battery is golden. I'm a diesel tech so I'm mechanically inclined there for mechanically inclined answers are appreciated. anything helps.

Terrys87

iTrader: (1)

Cleaning the Relay contacts helps. Replacing the contacts in the Starter helps as well. I get the contacts for the starter from Import Direct. http://api.viglink.com/api/click?for...ernator.com%2F

Rads fix below solved my click only issue and this as well >>> https://www.yotatech.com/forums/f199...l#post51975700

UPDATE:

This is how you would clean your starter relay contacts.
However, The procedure below did not fix the "click-only no-start" problem. Problem recurred. I reviewed schematic of 1986 to 1988 22RE cranking system and found a design flaw. Repair for the flaw is explained here.


I have intermittent no-start (crank) problem. Starter solenoid works and supplies power to starter motor when control (coil) terminal is directly connected to battery +.

I have verified that control power is getting to starter relay using method in earlier post (here).

With starter relay energizing, but starter solenoid not energizing, I suspect badly pitted /corroded starter relay contacts AND/OR ignition switch ST1 contacts causing high resistances and hence, excessive voltage drops.

To eliminate resistance of ignition switch ST1 contacts, I moved terminal 4 of starter relay directly to fused side of 40A fuse (see schematic here)

I was left with potentially bad starter relay contacts. I took starter relay part. Pic below shows starter relay with contacts open.


It is difficult to tell condition of contacts without a microscope and I could not find my 2000 grit lapping film, so I just ran 400 grit sandpaper a couple of times between contacts and blew clean with air spray can. That should remove any pitting/corrosion.


I'll monitor and see if I still have any starting issue.

How does the relay work?

One side of contact is connected to +12Volt (ideally directly from fused line directly off the battery and NOT through ignition switch as in schematic). Other side of contact is connected to control (coil) terminal of starter solenoid here.
One side of relay coil is connected to ground through clutch safety switch (when clutch is pushed down) or clutch safety cancel switch (if activated).
Other side of coil gets +12Volts from start contacts (ST1) of ignition switch.
Coil creates electromagnetic force and pulls armature toward it, closing contacts and causing current to flow to starter solenoid (piggybacked on starter motor). Here's a video of starter relay energizing (housing removed).
[YOUTUBE] [/YOUTUBE]

UPDATE:

The procedure above did not fix the "click-only no-start" problem. Problem recurred. I reviewed schematic of 1986 to 1988 22RE cranking system and found a design flaw. Repair for the flaw is explained here.


Starter Rebuild Video.

Odin

What Terry suggested could be it.

Since you're a mechanic I suspect you've checked how much voltage you're getting to the starter while you crank it? - Run voltage drop tests on both sides

Bad wires, missing grounds, and corrosion problems seem to be an infectious disease on this forum. Because the factory power and ground wires are thin these trucks really need to have them all in place and for them to be in top shape.

Make sure all of your ground wires are there, have clean contacts and the wires themselves are in good shape(low resistance).


The 22RE ground wire guide
https://www.yotatech.com/forums/f116...-guide-194413/