About half the time that I get into my truck and turn the key to start, I just get a clicking noise from the passenger side dashboard. Sometimes if I turn it extra hard too the start position it will go. Other times, it starts normal. Just curious if anyone has insight on if this is an ignition switch or starter issue. Leaning towards a starter issue since even when it doesn't go, I can here a click (maybe a relay) in the passenger side dashboard.

Truck is a 1990, 3.0, with 262k miles.

Thanks.

 

What you are hearing is most like the Circuit Opening Relay. Since that is downstream from the starter relay, the ignition switch is probably closing the starting relay. Since the starter doesn't turn with the starter relay closed, I would suspect the starter.

You can test it directly; pull the low-current wire from the starter, hook a jumper wire to the tab, and connect to 12v (making sure it is out of gear, parking brake on, etc.). If the starter doesn't turn then, you probably have (somewhat common) bad solenoid contacts. http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

 

Awesome! Thanks for the help.

 

Yes, you're hearing the C.O.R., Like Scope103 says^^

BUT, is your starter relay also clicking and your starter Thunking? If yes to both but does not crank, yes- most likely the Solenoid contacts.

However...
Seems like your truck is afflicted with Toyota's flawed wiring as documented here:


IF you have an automatic, the appox 12 amps needed to energize starter solenoid runs from battery, to cabin, to ignition switch (ideally not for carrying high current), back to engine compartment, down to transmission to neutral safety switch, back to engine compartment to the starter solenoid.

IF you have a manual, same high current runs from battery, to cabin, to ignition switch, back to starter relay in engine compartment, then eventually to starter solenoid.

Both above cases lead to too much power lost on the wiring and the contacts.

IF you're not into messing with wiring to check, just try jumping your starter solenoid with this while trying to crank. If it consistently makes your solenoid thunk and crank, then my theory is proven, and you gotta fix Toyota's messed up wiring - or add a hotshot relay.
I have a fix for it on my post but specific to starter relay on 22RE's. Different from 3.0's


If jumper consistently makes solenoid thunk but still does not crank, yes - bad solenoid contacts.

 

Wow, very interesting, thanks! The starter relay doesn't seem to be engaging, unless it's really quiet and I ma not hearing it. That's what seemed odd about this. Your theory may very well be correct. Once it gets a little warmer and I can get under the truck, I will see what's going on for sure.

Appreciate the help.