1986 pickup starter problems
If your Toyota P.U. will not start when it gets hot outside, you might want to read this thread.
I have a 1986 Toyota pickup that I have had starting problems with for almost 3 summers. I say summers, because it would not start when it was hot outside.
I have tried 3 or 4 starters (Autozone specials) and it would start great with a new starter, except when it was really hot. So today after it would not start again, I decided to do a little troubleshooting on my own. I pulled apart the Bendix portion of the starter and saw the brass thrust washer had less than 1/8" of an inch of contact with the positive a negative posts and thrust washer (contact points). So I filed off the thrust washer and contact points. Realizing I would be back doing the same thing once the contacts got cruddy again (wore out), so I decided to do a little additional "preventative maintenance". Seeing the contact points were only making contact by about 1/8" , I determined I needed to use the available space between the spindle and the contact points to increase the contact area. To do this, I simply added a washer behind the posts, (between the rubber insulator and the top of the bolt), pushing the contact closer to the center of the spindle. I took a regular round flat washer with the same hole diameter as the post or bolt and ground it square so it would fit inside the square rubber insulator. I did this on both copper posts or bolts. I then reinstalled the Bendix ensuring I had proper clearance, I reinstalled all of the parts back on the starter and installed it back into the truck. And wah-la the Toyota starts every time!!!
Unfortunately I did not take any pictures, and I wasn't going to pull it apart again just to show what I did. I figured a little information is better than nothing!