Did Toyota design the placement of the 3vze starter too close to the exhaust header? I recently changed my starter out to a Napa unit and my battery to a yellow top Optima. Yesterday was the only day this year it has gone over 30 degrees C (87 degrees F) here and the 4runner would not start. Click, click.

I bump started the rig and drove it into the garage. 5 hours later, I went out and it started as normal; did this about 10 times.

My thought is the heat from the exhaust expanded something in the starter to no make a connection.

Any thoughts?

 

The position of the starter in relation to the exhaust manifold has never been a reported problem as far as I know.
I'd suggest checking your connections on that newly replaced starter.

 

Check your starter relay. Are you getting enough juice to the starter? I've got an automatic - no relay and had to add one because the starter wouldn't turn when it was hot out.

 

It is not uncommon for new (rebuilt) starters to have problems internally. Also could be a wiring/relay/switch problem in your truck, have a look at this page for some ideas:

http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

 

before blaming the starter, i would check the grounds