Couple weeks ago I got the infamous "death click" when I went to start my '94 4x4 (22re), so I did a little poking around the forums here and found the most likely culprit was the contacts. I ordered a rebuild kit and replaced them, though the old ones didn't look all that worn when I pulled them out. Put everything back together, and had the same problem: a click when I turned the key, then nothing.

I had the battery checked, it's 100%, checked the starter relay and it's working properly, checked and clean the wiring and it all seems good. I finally took the starter in and had them test it at NAPA and they said, "Oh, your gear isn't popping out, it's defective." So I ordered a re-built starter from them and it came in today and I put it in, and three times out of four, the truck now fires right up.

But every so often, the starter will just whine and not engage. To me, it sounds like this NEW starter is not popping out; at least it is spinning, where the other one would just click. But what are the odds I have two bad starters in a row? I'm wondering what else could be wrong that would explain both problems? It really doesn't seem to be electrical, I seem to be getting good connections and power everywhere I can reach to test it, and on those occasions when the starter does engage there is no hesitation at all, it turns right over and fires up. I can't think what else to check... should I just keep swapping starters until I find one that works consistently? Or is there something else that could be going on?

 

I have got bad parts from auto parts stores before, so it is possible. A worn flywheel gear will cause a starter to spin and not engage, but it seems that you would have heard your old one spinning, also. I would pull the starter, inspect the flywheel teeth through the starter hole, and then return the starter while it is still under warranty if the flywheel looks ok.

 

Starter is bad. Get a new one.

 

Okay, thanks, I was afraid that was it... just bad luck, I guess.