1998 4runner ltd

My starter began to act up. I would get the loud click from the solenoid, but the starter would not engage or spin up until I had tried it a few times, and it was getting worse from one day to the next. I assumed the problem was either worn out solenoid contacts or brushes. I had replaced the original starter at 130k, and this 2nd starter had 160k on it so it seemed reasonable that it would be failing. The battery and cable connections checked out, and for the starter relay I took the lid off and cleaned up the contacts so measured resistance was below 1ohm. I could have done further tests but didn't. I figured there were 13yrs and between 10k and 20k startups on that unit (2 to 4 times per day)

Pulling the starter is fairly easy if you go in thru the right hand wheel well. First break loose the two starter mounting bolts. A 14mm 6point socket with a univeral and 2.5ft worth of extensions does the trick. For the upper bolt run the extensions above the trans support to keep that universal as straight as you can. Disconnect the battery, remove RH wheel & rubber flap. Three bolts hold the brake line in place. Once loosened, move the brake line segment towards the rear of the vehicle. The brake line is wound several times in a coil which allows you to move it several inches without creating any permanent bends. Detach the solenoid and battery cable from the starter. Remove the trans dipstick upper tube, and stuff a rag in the lower tube to keep it clean. Support the forward end of the starter so it won't fall, and remove the two bolts.

The trick to getting the loose starter out thru the wheel well is to orient it properly. Lift the forward end of the starter and pull it towards the right of the car, then flip the starter end-over-end so it is upside-down. The solenoid will be facing upward, and the drive gear will be facing forward. Point the solenoid and motor end caps towards the wheel well and wiggle it out (see pic). You will need to rock it back & forth and side to side a bit, but once the main terminal stud has cleared all obstacles the whole thing will pop out. No bending, pounding, bleeding (of any kind) or swearing required.
Reverse steps to re-install.

Took less than an hour including clean-up. One of the few times I didn't do things the hard way. I'll know in a few days if it really was the starter. Edit: Yes it really was the starter. How many miles/days do they normally last?

 

Did you replace your starter or just rebuild it? I’ve replaced my starter contacts on the one on my 22RE.

 

Since re-manufactured starters were only around $100, I replaced it. Since it seems to have fixed the problem, I am not that interested in taking apart the old starter to see why it failed. One thing to note is the ltd edition models came with a more powerful 1.8kW starter instead of the standard 1.4kW starter. They are interchangeable, and many parts houses/rebuilders do not mark their units. My reman starter was not marked, but included a test report saying it was 1.8kW. It kicks the engine over just fine. The starter I pulled out was a reman Bosch 1.8kW unit.

Toyota is offering a 20% discount on parts for older vehicles. Gives you an idea of their markup. A new Toyota brand starter for this vehicle would have been ~$210, but would need to be ordered.

 

My starter is original at nearly 449,000 miles. I’m sure I’ll get to follow your excellent writeup in the near future....



Andreas

 

Seriously? That has got to be some kind of record.

 

Serious as a heart attack. Never touched it since buying the truck new.



Andreas

 

So I posted here about replacing the starter on this car twice (the original and a 2nd reman). Well the third (reman) starter I put in only 28k miles ago has failed. The solenoid battery contact was, as is typical, worn away - but at only 28k instead of the usual 150k I have been getting. I can only conclude they didn't replace the contact at rebuild or used an inferior copper alloy. To save time I have now put in a 4th reman, just hoping they replaced the contacts with OEM equivalent parts. The actual work was the same as my posts above but the bolts were more stubborn. I used anti-seize on reassembly. Always run your bolts thru the starter threads before you put it in the car. If I hadn't I probably would have rounded off the top bolt.

In the pics you can see the worn battery terminal contact, and the only slightly pitted plunger contact and coil/brush contact.

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It was a Wilson brand reman sold by Pep, the company that decided to close all their parts stores in my state probably due to problems with returns and their special definition of what Limited Lifetime means. Like how it does not include wear. Advanced Auto bought out Pep, but claims they didn't buy the warranty liabilities. Try chasing that one down for maybe $50 credit.
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That's unfortunate.

I can't say how long mine have lasted...the original owner had already replaced the first with an aftermarket, sometime before 120,000 miles. Then I replaced that with a remaned OEM unit because I thought it was going out...but turns out it was my floor mat getting in the way of the clutch fully depressing , so who knows. Current remaned OEM starter has been in for 110,000 miles.