12v 2H starter issue

Joined
Oct 13, 2015
Messages
115
Location
Seattle, WA
I'm having some intermittent issues starting my wagon. Sometimes, I can't really tell when, although it's happened occasionally over years, when I turn the key, I hear a click but the starter doesn't engage. A couple of years ago I changed my batteries (it's a 12v system with the batteries parallel) but that didn't solve it. This summer, I replaced all my battery cables and grounds and that didn't solve it.

Then, I found the ignition to starter connector isn't weather-tight and is kind of grimy and I thought it was the problem until fiddling with it this morning did not fix my problem.

I finally banged on the starter with a hammer and that seemed to work, although without isolating variables or another test, I can't be sure.

The trouble is that a couple of months ago I took the starter to a local (Leavenworth, KS) rebuild shop and they said everything was fine with it and that it didn't need rebuilding.
starter picture 1.jpg
starter picture 2.jpg


Before that, I'd bought a 12v 2H starter from Amazon but it didn't fit my bellhousing (H55).

Any thoughts or recommendations on either where I could get a quality starter, what the part number is for the starter (can't read the data plate on the one currently installed), or anything else I should do? Like, should I get into the column under the clamshell and start trying to check continuity from the ignition? I didn't think this would be the cause since I do hear the solenoid click. There's actually two clicks: one when I turn the key to ACC and the next when I turn the key to IGN.
 
Joined
Mar 4, 2012
Messages
771
Location
Adelaide, South Australia
All factory 2H model vehicles have a starter relay which often causes a "click, no crank" fault when there's pitting on the contacts of that relay. I'm unsure what you have - your .sig says its an FJ62 converted to a 2H? So its possible you dont even have a starter relay.. if you do, pull it apart and given the contacts a light sanding with some 600grit paper.. The standard 60 series place for this relay to be mounted is on the inside of the right fender behind the airbox mount.. The 47 had the relay mounted in the passenger footwell.. If you dont have a relay I'd be wondering if the ignition circuit is actually flowing enough current to kick the starter solenoid into action - a simple test would be to supply 12V+ direct to the starter post with a nice thick bit of wire when the fault is evident.

Here's mine from my HJ60 that I recently fixed.

1573271454748.png
 

fjwagon

 
Joined
Dec 7, 2004
Messages
1,862
If you dont mind I like share one of my experiences on a diesel 45. I have a 1980 H engine and it was not easy to start it. It reminded me of a dying battery but it never died. I initially load tested the battery and watch it with a voltmeter as I applied the load. That was not it. I cleaned the cables at both ends, I cleaned the terminals at the starter. I tried replacing the starter but are hard to locate at a decent price. I finally found actual parts numbers for the components used on the 12v starter. I crossed them over and replaced them. What I found after taking the starter apart was one set of the brushes was worn. Inop. This starter has 4 brushes, 2 of them were not working. I took the brush assy. To alternator/starter repair shop and they "welded"...if that is what you call it. These brushes cannot be soldered with ordinary tools
Anyhow, criuser started like a champ.

And then one day the starter would sometimes not start the engine. After troubleshooting, I finally I used a remote starter and bypassed the relay. It started every time with no issues. With the help of an OEM manual I ended up taking apart the wiring harness apart and found a bad solder joint. I temporarily did a work around by using a vise grips to hold the wiring together until I got around to repairing it.

I recommend getting a multimeter and ohm out your connections point to point. From the starter to the ignition. Also repeating connectors may help. I agree with starter relay. To check it, energize it and ohm out the contactor in the close position. It may need a little cleaning. Be gentle when you clean it. Good luck.
 
Joined
Oct 13, 2015
Messages
115
Location
Seattle, WA
I do have an erstwhile FJ62 that was converted to a 2H/H55 maybe about 10 years ago? I don't know precisely. @torfab did the conversion, so I trust they did good work.

That said, can't find a starter relay. I did find this. I'm not sure if it's serving as a starter relay, though. I do have an email out to Torfab.

I've had the starter itself tested at a shop and they said it passed with flying colors.





I have a friend who's recommending a remote starter as well, and while that might be reliable, it doesn't solve the underlying issue. I'm also not sure how to run the lights and accessories if I use a remote starter switch instead of the ignition.

Thanks,

Ara
 
Last edited:

samwise

 
Joined
May 4, 2008
Messages
333
Location
Northwest Washington
Ive had a similar problem with my 3b, its rare though, but I havent been able to chase it down yet, Im guessing some sort of bad ground or wiring as mentioned above. I would look through all your relays though, glow plug relay, etc Sorry Im not more help with that.

While it sounds like your starter is fine, below is a link on swapping a new starting motor into a old housing, its for a 3b but might work for your set up as well?

If you find your cause please post.

 
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