I just replaced my old starter with a brand new oem starter after having to push start the truck a couple of times too many. After long drives it would not start, it would just click. Push starting it would seem to get it working again till the next long drive. Now the new one is doing the same thing. What else could it be? Seems pretty unlikely the new starter is bad.

 

How about a few more details about your ride. Year, engine, manual I assume since you can push start it.

 

It sounds like it could be heat soak. This is common with engines that are high horsepower (not likely with our trucks) or have headers close by, etc, where the starter gets too hot.

You might be able to solve it with a heat shield. Just my two cents.

 

Oh yeah, minor detail. 87 Runner, manual 5 speed, 22re, the usual stuff...

 

It does have header but wrong side. I also wondered about the heat, but it did it one evening after driving only 10 miles.

 

Check for a voltage drop from the wire going from battery to starter. There's probably a lot of resistance in there somewhere... loose connection, something corroded, etc that's amplified by the head of running your truck for a while, because heat will only add resistance to a circuit. That's probably where I would start

 

Yea, and the ground side too. If you have original battery cables, I would replace them. Corrosion in the cables may not be visible under the insulation. A weak battery may also cause the symptoms. Like PB4... said, a hot starter requires more current to operate and problems in the electrical circuit makes it worse.

 

So you are saying to check the voltage to the starter now while it is working and it should read something around 12 volts, and next time it acts up, it may read lower. That could be, but when it happens, and after I push start it, then the starter works fine, and the wiring would still be at the same temp...

 

Yea Id go with the wires , maybe loose or more than likely corroded ..

 

OK, let me check that out. Thanks Guys.

 

i upgrade to number 1 welding cable that I can get the cut off ends from damaged cables .

I then crimp on the ends and install the cables. I use Deka Marine terminals which have a stud and wing nut. They are also pretty cheap less than $5.00 a set . even lets say at a $1.00 a lug terminal lets say 3 grounds and one positive that would be 8 crimp on lugs . so for less than $15.00 I can upgrade one vehicle.

if you are having starting problems you can even run a new ground cable right to the bottom starter bolt

This has cured no end of charging and starting problems.

 

Problem solved. I cleaned and tightened all connections (which looked ok) and so far, after several long trips, she starts everytime. Thanks everyone.