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Starter Relay Re-Wire or Retrofit for 95 and earlier Trucks / 4Runner

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86-95 Trucks & 4Runners 2nd/3rd gen pickups, and 1st/2nd gen 4Runners with IFS

Starter Relay Re-Wire or Retrofit for 95 and earlier Trucks / 4Runner

Old 04-18-2019, 11:29 AM
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Starter Relay Re-Wire or Retrofit for 95 and earlier Trucks / 4Runner

This affects many trucks from first-gen pickups, to second-gen 4Runners / 3rd-gen pickups, so Im putting this here, as simple as possible, with necessary details and words to be effective, where it would be easier to find that deep in my own build thread. I will update with keywords, symptoms, etc for ease of finding.

Starter Relay Re-Wire OR Retrofit for trucks with NO starter relay and those with relays but wired wrong AT THE FACTORY.

*CAVEAT:
WHEN THE STARTER RELAY IS WIRED CORRECTLY SIMILAR TO LATER MODELS, IN THE UNLIKELY* EVENT THAT THE STARTER RELAY CONTACTS CLOSE* OR SHORT* FOR SOME REASON STARTER WILL CRANK EVEN WITHOUT IGNITION SWITCH BEING TURNED ON. IF PARKED IN FIRST GEAR, TRUCK MAY MOVE AND CAUSE AN ACCIDENT. A KILL SWITCH IN SERIES WITH THE RELAY CONTACT PIN IS HIGHLY-RECOMMENDED. JUST KEEP WIRE RUN TO MINIMUM.


The 1984 to 1991 22R-E's and possibly other models (see list of affected models) (https://www.yotatech.com/forums/f199...l#post52368225) have a common problem where when you attempt to start you only hear the COR click, but starter does not crank. Starter solenoid MAY click but weakly.
The problem may be intermittent or may not occur because a combination of starter solenoids with plungers that operate smoothly, healthy batteries, healthy wiring, and/or very good contacts may mask the problem.

Trucks before Mid-1986's do not have a starter relaY, (location shown in picture below).
1986 to 1988 with automatic transmission do not a starter relay, either.[indented=40px]Without a starter relay, the power to energize the starter solenoid has to travel over a long path (probably about 15 feet, illustrated here (https://www.yotatech.com/forums/f199...l#post52368224) from battery, to cabin, to ignition switch, back to engine compartment, and eventually to the starter solenoid. Wire resistance and that of ignition switch cause lots of power loss, so power is not enough to actuate the starter solenoid plunger completely. It also subjects ignition switch contacts to high current (approx. 12 Amps) that could shorten its life.

Here's how to add a starter relay:
Use a relay with at least 30-amp rating


Here's suggested construction of retrofit. Use 12AWG wire or thicker if adding a kill switch*:


*CAVEAT:
WHEN THE STARTER RELAY IS WIRED CORRECTLY SIMILAR TO LATER MODELS, IN THE UNLIKELY* EVENT THAT THE STARTER RELAY CONTACTS CLOSE* OR SHORT* FOR SOME REASON STARTER WILL CRANK EVEN WITHOUT IGNITION SWITCH BEING TURNED ON. IF PARKED IN FIRST GEAR, TRUCK MAY MOVE AND CAUSE AN ACCIDENT. A KILL SWITCH IN SERIES WITH THE RELAY CONTACT PIN IS HIGHLY-RECOMMENDED. JUST KEEP WIRE RUN TO MINIMUM.


Late-1986 and later with manual transmissions already have the starter relay, but they were wired wrong at the factory.[indented=40px]

ALWAYS VERIFY HANDS-ON EVEN IF YOU TRUST THE INFORMATION OR THE SOURCE.


ALWAYS VERIFY HANDS-ON EVEN IF YOU TRUST THE INFORMATION OR THE SOURCE^^^.

THE $11, HALF-HOUR FIX FOR starter relay that is wired wrong :
(Hot shot is off-the-shelf but it requires more work than the simple re-wire below)



*CAVEAT:
WHEN THE STARTER RELAY IS WIRED CORRECTLY SIMILAR TO LATER MODELS, IN THE UNLIKELY* EVENT THAT THE STARTER RELAY CONTACTS CLOSE* OR SHORT* FOR SOME REASON STARTER WILL CRANK EVEN WITHOUT IGNITION SWITCH BEING TURNED ON. IF PARKED IN FIRST GEAR, TRUCK MAY MOVE AND CAUSE AN ACCIDENT. A KILL SWITCH IN SERIES WITH THE RELAY CONTACT PIN IS HIGHLY-RECOMMENDED. JUST KEEP WIRE RUN TO MINIMUM.



Suggested Install Layout:



*CAVEAT:
WHEN THE STARTER RELAY IS WIRED CORRECTLY SIMILAR TO LATER MODELS, IN THE UNLIKELY* EVENT THAT THE STARTER RELAY CONTACTS CLOSE* OR SHORT* FOR SOME REASON STARTER WILL CRANK EVEN WITHOUT IGNITION SWITCH BEING TURNED ON. IF PARKED IN FIRST GEAR, TRUCK MAY MOVE AND CAUSE AN ACCIDENT. A KILL SWITCH IN SERIES WITH THE RELAY CONTACT PIN IS HIGHLY-RECOMMENDED. JUST KEEP WIRE RUN TO MINIMUM.


FIXED SO FAR:
Melrose's 1986 4Runner (https://www.yotatech.com/forums/f116.../#post52422300), For $15.
keywords:
click-only, no-start, no crank, nostart, nocrank, simple, simplified, concise, simple, quick, clickonly, clicknocrank, clicknostart, clickonly, starterrelay, wiringflaw

Last edited by RAD4Runner; 04-18-2019 at 11:39 AM.
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Old 04-19-2019, 02:01 PM
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Does this nullify the "clutch start cancel" button? I mean will this allow you to engage the starter by simply turning the ignition without the clutch depressed or the "clutch start cancel" button on the dash pushed?
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Old 04-19-2019, 02:03 PM
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Originally Posted by bearcat2 View Post
Does this nullify the "clutch start cancel" button? I mean will this allow you to engage the starter by simply turning the ignition without the clutch depressed or the "clutch start cancel" button on the dash pushed?
No, it will not bypass the clutch safety nor affect operation of clutch safety cancel.
It will only add a starter relay, if missing, or wire the existing starter relay the way a relay should be wired.

Last edited by RAD4Runner; 04-19-2019 at 02:05 PM.
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Old 05-11-2019, 04:43 PM
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Thanks

Just wanted to say I was getting the click no start issue on my 87 Auto 4runner, followed Rads instructions in his build up thread about adding a starter relay. Solved my issue.

Rad has also helped me understand how circuits work just from reading his many write ups, thanks Rad!
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Old 05-12-2019, 07:14 AM
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So 1992 and later 22REs w/a manual tranny are wired correctly?

Last edited by Paul22RE; 05-12-2019 at 07:16 AM.
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Old 05-13-2019, 05:35 PM
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Originally Posted by Paul22RE View Post
So 1992 and later 22REs w/a manual tranny are wired correctly?
Maybe yes, Maybe no.
Early Toyota's wiring was a Frankenstein clan.
Perfect example is JPL's 1990. Wired correctly but the starter relay is in the cabin, many feet away from the battery and the starter.

The only way to know is to be aware of the possibility of flaw and verify each and every case.
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