The other day, my wife told me our 97 4Runner's starter was running on even after it cranked. It even kept running after removing the key, trying to crank the engine without input from her. She stopped it by putting the key in and "cranking" the engine again. I can't reproduce this problem, but twice it has either given me just a click (and then immediately started) or nothing at all (still started on 2nd try). The starter spins the engine as fast as ever. The battery is a year or two old. There's 142k on the odometer.

Is this be a simple contact issue or do I have another problem with the starter? The dealership says the starter needs to be replaced.

Chris

 

I would start by replacing the contacts and then move onto replacing the starter if it comes to that.

Of course the stealership wants to sell you a new starter

Rob

 

My 97 4Runner is doing the same thing. Guess i'll try replacing the contacts.

 

I did some further reading and searching here and on the Internet. It appears the problem with the starter not disengaging is the plunger in the solenoid. That is a replaceable part as well. I'm going to order the contacts and the plunger and do the job myself.

Chris

 

Pull the starter out and give it a good going over:
- http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

Could be dried/dirty grease is causing it to stick on, could be unevenly worn contacts causing the same problem. How? Plunger hits the contacts with a ring (contacts 180 degrees apart) and if one contact is worn lower, that can cause the plunger to get "cocked" in the bore of the solenoid and get stuck.

 

Ford's back in the late 80's, early 90's were infamous for this. Turn the key to start and the starter would just keep on goin. Pain in the ass. If I remember correctly it was the solenoid that had some bad contacts. I would start there like you mention reading about elsewhere.

 

I went ahead and ordered the contacts and the plunger from the local dealership. I'd rather have the parts on hand and not need them than get halfway through a job and need parts that can't be had till the next day. Or worse, have to tear into it again...

Chris

 

Finally got around to doing the job. It took less than an hour including cleanup. I didn't have to disconnect anything other than the starter and the battery. Very easy job!

I replaced the contact, the plunger, and the return spring. I probably did more than I needed to do, but I wanted to make sure I didn't repeat the job. One contact was very eroded, the plunger was worn, and the return spring was nearly a 1/4" shorter than it's replacement.

Since the problem was intermittent, I won't know if I was successful for at least a few days.

Chris

 

How much did they charge you for the parts?

 

Check his site...

 

About $50 in parts, but I replaced everything that could cause my symptoms rather than risk having to do it again. No problems since...

Chris

 

That is pretty quick. Did you not have to disconnect the swaybar??

 

A rebuilt starter for my 87 pickup cost less than $50 and I didn't have to spend the time