I just got the starter relay click thing with no start and have read enough to figure it is probably the starter contacts that are worn. Looking at all the repair manuals and such I see no mentioning of starter contacts, just the brushes. Are those the same thing or am I all stupid here not understanding what is going on inside the starter?

Any help is highly appreciated.

 

The contacts are inside the solenoid that is attached to the starter:
- http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

The brushes are inside the starter motor itself, worn brushes usually result in slow cranking and/or overheating in the motor itself.

 

read 4Crawlers page before doing anything. You may find it's not the contacts causing the problem and he DOES have information regarding that too.
I went through his page and found out that my ignition switch contacts were weak (91 22re / automatic), wired in an external relay actuated by the ignition switch and my problem went away.

 

Oh cool, thanks. Took a look at my wiring diagram and it looks like there is a straight path from the battery to the starter when the relay closes. Doesn't run through the ignition switch or anything. I guess I'll check the connections first and go from there.

 

just 'cause your wiring diagram shows it, doesn't mean it is. it seems there are almost as many diagrams as there are toyota trucks.
test the wires to verify.

 

I guess you are right, although I do have the actual FSM book for my year 4runner, so I think at least that part is as good as it gets.

 

well then, test that the proper terminal on the ignition switch goes hot when you go to start the vehicle and go from there.

 

Ususally my pattern has been that the car wont start after either sitting overnight or after a day of work. If it sits for just a couple of hours it starts right up. This morning however it started right away I guess the contacts just happened to have good enough connection this morning (or a wire or whatever it is that is causing the trouble). I will try to measure the voltage at the wires this afternoon.

 

Since you have this somewhat repeatable pattern, you can try to measure the voltage (under load) when it starts fine and when it does not. Then you'll have something to compare with and see if there are any differences. And if you see no differences in voltage, then you are looking at something inside the starter, likely the copper contacts inside the solenoid.

 

Did a quick measurement and I had voltage withing 0.3 volts of the battery voltage when cranking the starter. Took the starter out and discovered a badly worn contact on the battery side. I'll add a picture later on. I got the original contact, which included all the surrounding little pieces, from the dealer (PN 28226-70040), and the contact had the "ears" or whatever you want to call it that contact "D" from 4crawler's website. I guess that gives a lot bigger contact area.

Anyway, did the replacement and put the starter in, and now it starts like a dream again. Thanks to you both for the help and info.