Starter noise/clunk

[Brian894X4]

I knows others have experienced this and now I'm really wondering what's going on.

It started out with an aftermarket starter (unknown brand) that the PO had installed before I bought the rig. On occasion, with seemingly no ryme or reason, on start up, the somewhere in the middle of cranking, there would be a thud or clunk noise.

I later replaced the starter with an OEM remanufactured unit when doing a bunch of other PM and while the problem is still random, it's more frequent and occasionally louder and more disturbing. Sometimes instead of a light clunk, it's a loud clunk and then the engine starts.

I have a theory on this. First the problem seemed to be related to my letting up on the key to soon, like the starter gear was retracting too soon or retracting and then reengaging while the motor was still turning. I've tried to make sure that I give the key a firm turn and don't release it until the motor starts, but the problem still persists.

My only guess is that like I said, the starter is retracting and reengaging and hitting the flywheel teeth as the motor is sort of turning over. Unless I had two dud starters, I guessing the problem is not the starter. I know others have had this issue as well and I've never had this come up on any other car, but I'm guessing there's something in the wiring or ignition switch.

I wonder if the switch is just losing power intermittently or maybe the contacts are dirty or something. Another thing I'm wondering is that the starter I put in is the heavier duty high amp starter and it looks indentical to the one I took out, so I assume it was the higher amp as well. I wonder if the factory wiring that might be designed for the lower amp starter, might be putting too much resistence and causing the starter to hesitate mid through the starting cycle.

Anyone have a theory or ideas on this one? Seems to be a fairly common issue on the LC80s. At least I've heard it mentioned here several times.

[IronYuppy]

I don't know what the issue is, either, but FYI I have the same problem (two different starter motors - OEM and an aftermarket reman) with a bypassed factory ignition switch. My truck starts with a starter button, so the power is steady and not subject to any fluctuation/flaw from the factory switch. I still get the clunk. I wonder if perhaps this is a design flaw in the starter itself - maybe it is based on the 24v starter found on the HDJ81, and 12v sometimes doesn't let the gear retract in time? Just throwing that out there. I'm really stumped, actually.

[Brian894X4]

Well, that does narrow it a down a bit. I wonder what a nice fresh, bigger gauge wire from the battery to starter would do.