Well.. i finally got around to taking the starter off and looking at it.. The two copper contacts look a little worn but not too much.. The plunger in the starter on the other hand was very bad. The little copper ring on it is all pitted and was pretty tarnished. I cleaned all of then really well hoping to get some more starts out of it. The ring on the plunger looks permanently attached to the whole set. I know the starter rebuild kit (sold by Toyota) includes the two copper contacts, but does it include the ring for the plunger?? Can i buy a new plunger?

 

hehe.. no one know?

 

i just pulled the starter in my 90 and bought the starter repair kit but it only included the copper contacts. only one contact at that. i bought a second one, installed them, sanded the disc and cleaned the whole area with electrical cleaner and she starts like it's new even after 157k.

 

The plunger does not come in the kit as far as I know.
Your best option (most trouble free anyway) then is to buy a rebuilt starter.

 

dealerships sell the plunger as well. buy it and do your own rebuild

 

It does not come with the kit. By the time you get done paying for all the pieces, you will have spent more then the cost of a rebuilt starter motor, with a lifetime warranty.

 

Mine was worn the same way. The starter crapped out on a Sat evening, so I couldn't get any parts. I spot welded all the pitted contacts and ring. I used a car battery and a piece of rod to do the spot welds. I kept adding to the contacts then filed and sanded. It actually looked very good. It must have worked because it hasn't quite for about 60,000 miles. BTW, don't buy an aftermaket starter. They are junk. Fix it youself. It will let you see how it works, and I found much cheaper. I rebuilt my sister in laws with new contacts from Toyota for less than $20. If you haven't seen this site http://4crawler.cruiserpages.com/4x4.../Starter.shtml check it out. He also has some good links. You can buy the bigger contacts from him if needed.