Ok... Last fall, when I would drive my truck for a while and it would get warm / hot, I could get out of it to get gas, and when I would get back in it, it wouldn't start. The starter wouldn't even turn over. So, a guy that rebuilds starters and alternators told me that the stuff inside the starter would get hot and expand and lose contact inside, so let it cool off and then it would start. Turns out he was right... For a while. Worked good all winter, and started back in this spring. So I had him rebuild the starter. Worked for a few weeks, and same problem came again. I called him back and he suggested having the battery checked. Battery had no CCA, so I replaced the battery. Few weeks later, was coming home one night and the lights went out and truck died. Alternator bad, so I had him rebuild the alternator. So, here's the new problem: Reinstalled the rebuilt alternator, and the brake - charge - at oil temp lights are on in the dash, the headlights are acting all goofy, and last night the starter wouldn't kick back over until I tapped it on the side. What the heck is going on with my truck? I'm calling the guy back tomorrow to get his next opinion, but wanted to hear yours to check his story. Thoughts? Any help would be appreciated... The weather is finally settling down here and I'm wanting to get the top off and enjoy the summer the 4Runner way...

 

Sounds like your alternator was not rebuilt correctly, or was not installed correctly. The brake, charge, and a/t oil temp lights are indicative of an alternator that is not charging.

Your no start problem could be the result of a poor wire or ground connection somewhere. A voltage drop test would confirm this. Get yourself a multimeter and google "starter voltage drop test" and you should find instructions on how to do it.

 

Your alternator is still bad, are you sure the guy that rebuilt it knew what he was doing ?. Try replacing the power wire that goes from the battery to the starter, they can go bad internally but still look like new on the out side.

 

all great suggestions guys, but if I may add my $0.02..... Before you go chasing down your electrical gremlins, always start with making sure you have a proper ground(-). Check and make sure you have good, clean, tight grounding from your frame to engine, body to frame, engine to body, battery to body, etc........ Start there and then move on to your components, alt., starter, relays, etc..... It's like building a house, even if the walls and floors are BA, it don't mean nothing if the foundation sucks............ good luck!

 

yes good post by stepside.

Could be as simple as a bad cable end of the positive or negative cables. The fact you beat on the starter would seem to indicate it is within there, but could also just be coincidence. Read up on the 4crawler.com website that Roger Brown is a genius of most things electrical such as this. You could perhaps do your own contacts or check them.