[TJS8040]

Long story short, I had some duplicate ignition keys made. Today I started my stock '80 with new key, all sounded well. After a few miles, I heard engine noise that sounded like a belt problem. I checked belts - they seemed fine, gauges were good so I drove another 10 miles and noise went away. When I shut it down, the ignition key was stiff and tight when I turned it off. I could not restart, no click, no nothing, battery power was fine. Starter motor was hot, hot, hot. I'm now thinking that starter was engaged or partially engaged the whole time. Triple A delivered me home, the top is off for the summer. I am a novice mechanic- I'm a good replacer and terrible troubleshooter. Should I just replace the starter? I sucessfully replaced the solenoid on my 80 series - what is a good starter source for the 40 series? Do I replce just the starter motor - there is power coming from the solenoid.

[Phrog]

It certainly sounds like the starter...it's possible that the new key
was stuck in the 'start' position, meaning the starter couldn't
disengage.

I would check wiring first, however, just to make sure. Check that
the starter has a good ground. Then run +12V directly from the
battery to the solenoid (make sure you're in neutral first), and
see if the starter responds. If the ground is good, and the starter
doesn't respond to +12V, it's likely that the starter is cooked.

There are several threads on the pros and cons of various
sources for new starters. In brief - Toyota OEM remanufactured
are high quality but expensive, NAPA or other aftermarket are
cheaper but variable quality. It's also possible to put an FJ60
starter in a 40.

I put a NAPA starter in my FJ40 a few months ago, so far
it's working fine.

-Phrog

[Doug_S]

A similar thing happened to me when the solenoid on the starter stuck in the "on" position during starting. I could clearly hear the starter motor engaged on the ring-gear so you'd have probably heard it too. I doubt if the starter stuck in the "on" position. You may be dealing with just a bad starter with some sort of an internal intermittant short. Just a guess though.

[Moe R]

Would your starter click once in a while when you would engage the starter? Your contacts may have seized, welded together, and probably tosted the starter. That's what happened to mine.

[TJS8040]

Thanks all for the advice. Phrog - I connected a wire directly from the battery to the starter, no response. I have power coming from the ignition, so I ordered a new starter. After reading the threads I went with the gear reduction starter from toyota. I'll let you know how it goes.

[surfpig]

Originally Posted by TJS8040

Thanks all for the advice. Phrog - I connected a wire directly from the battery to the starter, no response. I have power coming from the ignition, so I ordered a new starter. After reading the threads I went with the gear reduction starter from toyota. I'll let you know how it goes.

It's a one job. You will be pleased with it.

[fjwagon]

You can always remove it and have it tested at any local auto part store for free. Some have lifetime warranties others don't. I would also ohm out the iginition switch to be on the safe side. This is easily done by disconnecting it and checking it with an ohm meter at the connector. They tend wear out to the point that they will turn on a starter without you knowing after starting it or they will sometimes not turn on the starter even after you turn the key. Also inspect the wiring before replacing the starter.

Try getting a newer starter( gear reduction type) They use less power and is easier on your battery.

[TJS8040]

Thanks all. Starter replaced - I'm back in business.

[bsmith123]

you said your ignition was stiff with the new keys---still works good with the old ones right? you dont want a repeat

[TJS8040]

Certainly not - new keys canned.