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Starter solenoid contact fix

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Old 10-02-2009, 01:50 PM   #1
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Starter solenoid contact fix

This is my own version of the 22re starter solenoid fix. 4crawler did an excellent job, but I feel his pics are small and blurry. So I took better ones.

My truck would randomly just click and not start. Then it would start. Went away for weeks at a time, then just hit me and every time I tried to start it it would just click.

Anyway, I first removed the starter.




Next, I cleaned the starter a little bit then took it to the work bench. Where I then inspected it. I then took off the cover with three little bolts. I used a wrench to loosen/tighten them.


Here is the plunger thing coming out.




Here is what I will be replacing. See how worn out it is?


I then removed ONE contact at a time. I decided to do the really worn out one.


In order to get it off I stuck a small flat-head screwdriver between the copper bolt and the contact.

In order to get the new one back on. I carefully used a vice to squeeze it back on. Just be careful.

New vs. old




Now, I put it back on. One at a time. Next will be the left one.


Next, I did the other side. It was easier because the contact did not have to put be forced on. Just remember where everything went.


Next, I put the cover back on and cleaned the starter. Now its ready to go in!







The contacts were $11 each. I couldn't wait to buy them online as my truck is a DD. So I went to the dealership and they had them in stock.

This took about 3 hours from start to finish because I am slow and decided to clean it. It could be done faster.

Big thanks to 4Crawler and his site....http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

Last edited by 91Toyota; 10-02-2009 at 01:53 PM.
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Old 10-02-2009, 07:19 PM   #2
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Surprised no one replied to this
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Old 10-02-2009, 07:23 PM   #3
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yep .. good job !!


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Old 10-02-2009, 08:46 PM   #4
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Great pics!

Pretty you could get 95% of Toyota starters to work again by replacing that one burned up contact.
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Old 10-03-2009, 06:07 PM   #5
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Nice pics. Did this to mine also. Then fixed the neutral start switch, which I believe was the real culprit. Then added a starter relay when I did the alarm. Now she starts every time with authority!Yotatech rocks!
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Old 10-03-2009, 06:15 PM   #6
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Surprised no one replied to this
Your just unpopular, dont feel bad

Jk

I used to always replace a funky starter til i figured this out a year or so ago now they last 3 times as long. Good write up
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Old 10-03-2009, 06:49 PM   #7
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Yes good write up. I too used to replace too many starters. Those days are over.

Now I just need to get a better idea of where to tap in to do the starter relay. My ignition switch lags a tiny bit every time.
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Old 10-05-2009, 02:31 PM   #8
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Thanks guys....i'm just hoping this could help someone out one day.
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Old 10-05-2009, 02:44 PM   #9
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Congrats, you just built a Schucks reman starter!

You could make MILLIONS! Feels good to do it yourself, eh?
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Old 10-05-2009, 03:03 PM   #10
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Congrats, you just built a Schucks reman starter!

You could make MILLIONS! Feels good to do it yourself, eh?
I could be an astronaut now? Please
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Old 10-05-2009, 03:40 PM   #11
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Thanks for the great pics. Much appreciated.
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Old 10-05-2009, 08:13 PM   #12
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Yes good write up. I too used to replace too many starters. Those days are over.

Now I just need to get a better idea of where to tap in to do the starter relay. My ignition switch lags a tiny bit every time.
I love wiring
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Old 10-05-2009, 08:26 PM   #13
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Nice pictures and explanation. Many who don't know about this simple fix trade in an excellent factory starter for a POS.

I replaced my contacts years ago. Could probably have only done the bad side, but I had already bought both.

In my stock 86 the hardest part, which actually was quite a chore, was working the starter out and then back into position. I just pulled mine again and didn't have much trouble, though the clutch slave cylinder was disconnected.

BTW, when your contacts begin failing, but before they totally crap out, a few taps with a hammer or whatever on the solenoid housing will usually jiggle things around enough to get the starter to engage. It won't work for long though.
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Old 10-06-2009, 07:45 AM   #14
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I could be an astronaut now? Please
Trev and his fellow astronauts in space:

Guy: Oh my god! Were having a malfunction

Other guy: Then engines wont fire!

Other guy: What do you think Trev?

Trev: ...wheres the starter at? That pesky moon dust got in and gummed up the contacts!

Last edited by algranger; 10-06-2009 at 07:46 AM.
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Old 10-06-2009, 08:41 AM   #15
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Good job, thanks !
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Old 10-06-2009, 10:27 AM   #16
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Ok so I replaced my starter contacts about a month ago because I was getting the click. They were pretty worn out. Just yesterday I went out to start the truck and I get the click and I had to hit it with a hammer to make it start. Would something else make the starter make the "click" besides worn out contacts?
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Old 10-07-2009, 08:01 AM   #17
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Loose conections, such as hot wire or ground wire. Weak battery. Those come to mind, but I would check connections first since you had it off a month ago.

Last edited by crafthorse; 10-07-2009 at 08:02 AM.
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Old 10-07-2009, 08:20 AM   #18
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Ok so I replaced my starter contacts about a month ago because I was getting the click. They were pretty worn out. Just yesterday I went out to start the truck and I get the click and I had to hit it with a hammer to make it start. Would something else make the starter make the "click" besides worn out contacts?
Yes, X2 on the above, see below for a quick test to help identify the problem source:
- http://www.4crawler.com/4x4/CheapTri...shtml#EasyTest
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Old 10-12-2009, 02:09 PM   #19
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I love wiring
Can I use the big pos battery cable coming from the battery to the starter as my power into the aftermarket relay?

My switch is definately going bad. Sometimes it doesn't start and then if I back off a little with the key it kicks over like normal.
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Old 10-12-2009, 02:18 PM   #20
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Can I use the big pos battery cable coming from the battery to the starter as my power into the aftermarket relay?

My switch is definately going bad. Sometimes it doesn't start and then if I back off a little with the key it kicks over like normal.
That is how I wired my Painless HotShot relay:
- http://www.4crawler.com/4x4/CheapTri...l#OtherOptions

The Painless kit does include a 30 amp circuit breaker to protect that wire, since it runs directly from the battery to the starter with no fuse.
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1991, 22re, 4runner, 95, boat, bypass, contact, contacts, fix, hot, location, shot, solenoid, starter, switch, testing, toyota

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