mt4runner

My '91 runner (3.0,5spd) has been giving me a fit lately. A month ago I took a road trip of a couple hundred miles. Pulled in the driveway, shut it off, unloaded some gear, went to put it in the garage and it wouldn't start. No clicky at the starter, just gauges moving like they do when you start. Went to troubleshoot the next day, hit the key and it started. So I checked all the grounds, and cleaned the starter cable and stud. Everything seemed to be working well. Took another longer trip this weekend, stopped for gas after about a 100 miles, and no start. My research show three possible problems. Starter contacts, relay or the electrical part of the switch. I've got the contacts and am going to replace them first. I'm not so sure about the relay, I'm thinking it would just crap out and not work intermitantly. And I haven't found any reference as to how to test the switch. I'd appreciate any advice from the knowledgeable folks here. I'm tired of worrying about this and always parking with the nose downhill. Hate to get stranded back in the mountains this hunting season.
Regards,

myyota

If its the original starter, then the contacts are probably shot. Replace them and let us know what happens.

xxxtreme22r

most likely the contacts, and you may or may not get away with changing out the plunger, but if it were me I would go ahead and change the plunger anyway.

mt4runner

Thanks for the input. I'm going to replace the contacts soon. Would be starting on it tonight, but have too many honey-do's to finish this evening. I do plan on using the original plunger if I can clean it up well enough. Just did a contact R&R on my sons' '95 last month, and we were able to clean it up and make it look like new.
Regards

MB4runner

Well... besides fixing it. You can hit it with a hammer Mine is doing the same thing after I went through deep water. So to get me through until I fix it I just bang it with a hammer and it magically works.

xxxtreme22r

if the plunger is pitted at all which can happen when the contacts go out because of the arcing I would replace it.

mt4runner

xxxtreme22re, I'm curious as to why you would recommend replacing the plunger if its pitted. I will agree that, if it is severely pitted and it won't clean up, then it should be replaced. My sons' plunger was lightly pitted, chucked it up in the drill press, applied a little emery cloth and it looked GTG. Stealership has the plunger in stock, big $$$$$'s, so if I need one I'll cough it up and buy it.
Regards

xxxtreme22r

I just remember what mine looked like before I put a new one in to do mine. I picked up the plunger and contacts from a local auto electric shop that rebuilds starters and alternators. I do not remember spending more than $20 for both the plunger and contacts.

removing material from the lip of the plunger IMO is not a good idea. Almost defeats the purpose of putting in new contacts..

mt4runner vs MB4runner boy that's kinda confusing had to look twice to see if it were the same person haha.

mt4runner

Hard to argue that point. Guess I'll be picking up that plunger.

Rusted Rooster

Hammer work 4 me too...if your in a bind,

TNRabbit

The hardest part will be taking the starter OUT~

mt4runner

TNRabbit, I hear that. Took a while when we did my sons' starter. Now that I know exactly what needs to be done to remove it, shouldn't be too bad. The whole job took about 3 hours on my son's 'runner, I think I can cut that in half this time around. I did try to tap on the starter, but there's not enough room to do that on my runner, or I'm just hammer challenged. I'm still wondering why it only acts up after everything is good and heat-soaked, but hoping the contacts will cure the problem.

TNRabbit

Double-check ALL your major ground wires, too (battery to body, body to frame, frame to engine).

mt4runner

TNRabbit, will do. I also had my battery tested a few minutes ago, might as well start at the source. They don't have a load tester, but, it only showed 235 CC Amps, and today it is 72 degrees here. The battery is rated at 750 cc amps, 500 at zero degrees. So I am replacing it in the a.m. Still going to do the contacts, but I am beginning to lean more toward a power supply issue.
Regards

mt4runner

Stater is on the bench and disassembled. The contacts are toast, and the plunger is pitted so badly that contact is only made on pin head sized areas on both the plunger and contacts. I can't believe that it would even start at all, considering the conditions of the old parts. Going to town to pick up a plunger. Hopefully this will cure my no-start issues.

mt4runner

Also, the boot that protects the post attached to the starter self-destructed when I removed it. Any advice on dealing with that. I was thinking some shrink wrap might do the job.

camo31_10.50

Good deal for fixing it instead of replacing it!

xxxtreme22r

hehe sounds like how mine was. That's why I tell everyone to get the plunger as well.

xxxtreme22r

if it fits around it, an old spark plug boot would work. Been there done that as well, just not on my Yota.

mt4runner

Took a road trip yesterday. 240 miles round trip, with a 3 hour layover, plenty of time for heat soak, and no problems. Starter never sounder so good! Other good news is I found a starter repair shop that sells Denso parts. Picked up the plunger for $10.50 vs. Stealerships' $38.95. Also, they have the breather tubes and any and all insulater pieces. To boot, the guy is super nice, great customer service. Life is good!