OK, a few months ago, I tried to start my truck and the starter went "click." So I searched, found out about the contacts, and replaced them. While I was in there, I thoroughly cleaned all the connections between the starter and the battery. That helped for a bit, but recently I had to start hitting the starter with a hammer before it would start, and now it won't turn at all, hammer regardless. I'm thinking that the starter motor has gone bad. I saw in the FSM that you can rebuild the starter motor, but is it worth it? Would it be better to just buy the reman'd one? If the motor can be rebuilt, are there any tips I should know aside from what it says in the FSM? Does there happen to be a how-to guide? Thanks in advance!

 

Have you checked your battery cables and such?
Are you sure you lined the started up correctly on the flywheel?

 

I haven't checked the battery cables since I installed the new contacts, but I can hear the solenoid engaging, so I'm assuming the wiring is fine.

I'm not sure what you mean by lining the starter up with the flywheel. I followed the FSM, securing the starter with the two bolts (the one behind the starter is a bit of a pain), and it's been starting for months after that job.

Can anyone help?

 

A week battery or bad connection can engage the solenoid but not turn over the motor.

That said, I would rather turn it in for a rebuilt replacement instead of trying to rebuild it myself. It's a few more bucks but you can almost always get a 1yr (or better) warranty out of the rebuilt unit.

Also, some places can bench-test your old starter before you commit the funds.

 

Might try this quick test to see if the problem is in the starter or not:
- http://www.4crawler.com/4x4/CheapTri...shtml#EasyTest

And when you say you hear the "solenoid" click, are you mistaking the sound of the circuit opening relay in the passenger kick panel area for the solenoid click?

 

I don't think it's the battery, my electrical system powers on just fine, it's just that the starter doesn't turn. And I double-checked that the solenoid is engaging by holding it while someone else turned the key, and yeah, I felt it jerk, so it's working. I still have to check that the starter's getting power, though.

 

The solenoid can move a little with lower voltages but to get a good had pull enough to compress the Bendix gear spring takes a pretty healthy current and voltage. Also it may be dirty inside the bore of the solenoid. If you did not clean it when you replaced the contacts might be good to check that out.

 

You can get a remanufactured Denso starter at www.partstrain.com for around 75.00 dollars, i have one on my 86 4Runner and it works good, no problems with it at all.

 

I cleaned the disc that touches the contacts when the solenoid is engaged, I'm not sure if that's the bore of the solenoid. Still need to check the voltage coming off the solenoid, but it's raining right now.

 

Autozone Starter- $69.95
Lifetime Warranty- Priceless

 

I got a working stock starter I can sell.. $50

 

Drove my truck all day today, got home, was on my way out to the grocery store, got in the truck and... "click". I sympathize with ya Zelephant. I also considering the same question... Repair or Replace? Where do you stand so far?

 

Test:
- http://www.4crawler.com/4x4/CheapTri...shtml#EasyTest

and if the solenoid contacts repair:
- http://www.4crawler.com/4x4/CheapTri...rter.shtml#Fix

and if not fix the underlying problem:
- http://www.4crawler.com/4x4/CheapTri...l#OtherOptions

and why fix instead of replace?
- http://www.4crawler.com/4x4/CheapTri...epairVsReplace

 

I got a voltmeter on the starter today and got some funny readings.

First, I measured the voltage at the two battery terminals. It was even at 9.57v. Then, I measured the voltage at the heavy power cable running from the battery to the starter motor; it measured the same as the battery with the ingition off. When I had my brother turn the key, the voltage at the motor end of the cable dropped to somwhere between 8 and 7 volts. I also checked the power at the small solenoid wire; it mercifully read 0 with the ignition off, but ony about 7v with the key turned. I'm beginning to think it could be the battery. Thoughts?

BTW everyone, but particularly 4Crawler, Thanks a lot for helping us newbs out!

 

9.57 sounds like an issue.... if your volts are down to 9.57 I wonder what your amps are at..

try it while you got some jumper cables or a booster pack on see if you have an issue starting it then..

 

How old is your battery?

Standing voltage of 9.57 is a dead battery. Probably not even enough to actuate the solenoid.

 

Yep, sounds like a weak battery at lest. And if you see more than 0.5 volt difference between the battery and the solenoid wire, that is indicative of a wiring issue there.

 

Can you elaborate on wiring issue? Wht should I be looking for and where should I look to fix that?

 

Most common issues are loose connections/connectors or wiring that is corroded or broken up underneath the wiring. The way to find the problem is to measure the voltage drop at various points along the circuit looking for where the majority of the voltage drop is coming from.