91 Land Cruiser Starter Failing (5 Viewers)

[Demonic92]

Hey all,
I know this has probably been covered on here before so I truly apologize in advance, but I just want to make sure I'm approaching this the right way.

My 91 (now with 274k miles) has had intermittent starting issues going back to about 2021. I've always been able to fix it by having someone else turn the key while I hit the starter with a hammer, so this obviously points to something wrong with the starter. I have full service records back to 1991 and it has never been replaced/rebuilt before. Recently the problem has been getting more consistent, with it maybe happening every 5-10 starts, and sometimes when I'll turn the key it takes multiple seconds for anything to happen, which I assume is related to the same issue.

If someone can confirm that this is in fact the starter and not something I haven't thought of, would the rebuild kit fix this kind of issue? Is the rebuild kit still available? Or should I drain my wallet and just replace the starter entirely? I want to keep everything OEM Toyota parts and I assume the OEM starter is not available anymore. The only factor I guess is if the rebuild kit will solve this problem I'm having.

Appreciate any wisdom, and also any trash-talking as this has probably been asked before. Thanks in advance

 

[robnicko]

just put a new set of brushes / plunger in it and youll be fine
it sounds like the plunger is sticking plus if original the contacts would likely be in need of a refresh
its a very simple job

 

[Demonic92]

just put a new set of brushes / plunger in it and youll be fine
it sounds like the plunger is sticking plus if original the contacts would likely be in need of a refresh
its a very simple job

Okay cool. So will need brushes, plunger, and contacts? Or do the contacts just get cleaned?

Does anyone know the part numbers for this stuff?

 

[robnicko]

Just get a rebuild kit from either Toyota / auto elec or Ebay, its likely a Denso starter

 

[Demonic92]

Just get a rebuild kit from either Toyota / auto elec or Ebay, its likely a Denso starter

I just have to confirm which starter I have right? Since there were a few versions for the 80. And then buy the correct rebuild kit for it?

 

[Kernal]

Go to Partsouq dot com, type in your VIN, that will bring up the parts diagrams for your entire vehicle. Then start searching,
easiest method is to click on Search, then type in Starter, then click on the diagram, then look at the parts. The rebuild kits however may not
be listed but it will get you in the ballpark.

Or, go to any online Toyota parts dealer and search for Starter.

Here's one link, a completely re-manufactured Toyota starter for a 1991 FJ80 is not that much more than the cost of the two rebuild kits
you need. However those kits would only replace the contacts, plunger, and a few other small parts. The bearings, armature, brushes
are not included in the rebuild kits. There are other components inside a starter that can wear ie: the clutch, pinion gear, etc.

https://toyotaparts.ourismantoyotaofrichmond.com/oem-parts/toyota-starter-remanufactured-281006007084?c=bD0xJm49U2VhcmNoIFJlc3VsdHMmYT10b3lvdGEmbz1sYW5kLWNydWlzZXImeT0xOTkxJnQ9YmFzZSZlPTQtMGwtbDYtZ2Fz

 

[COS80]

Search my click/no start thread. I think the contact p/ns are in there.

I recommend you do this yourself and don't buy a rebuilt. I was disappointed to find that my starter was rebuilt, was I got it out, and the reason the contacts were shot was because the rebuilder skipped the steps in the FSM to seat the contacts. This was abundantly clear by the unevenness of wear. It wasn't even hard to do.

 

[Kernal]

Agree, depends IMHO on whether your starter is the original or an aftermarket starter. But then again if the OP's starter is the original it's 34 years old.

Compared to buying an aftermarket rebuilt starter it may be a better route to replace the contacts and plunger of your original Denso-Toyota starter (assuming your starter is the original). One reason however to buy a Toyota remanufactured starter (from a Toyota dealer) is that it's currently available (for a 34 year old vehicle). AFAIK they aren't reman'd in Japan anymore but still would be a better choice than most no-name aftermarket starters.

From above, here's the part numbers for the rebuild kits:

28235-54380 : ~$20-25 (Price depending on discount, where purchased)
28226-72010 : ~$30-35
28226-66060 : ~ $20-25

Total: ~70-85 (plus taxes and shipping) for contacts and plunger and a few other small parts.

So you can partially rebuild your starter for ~$70-85 plus shipping and taxes, or replace your starter with a new OEM Toyota Remanufactured starter for ~ $85-140 (depending on where you buy it, discount, plus shipping, taxes).

IMHO having completely remanufactured a Toyota-Denso starter myself I found that the original grease after 20+ years dries out, that's both
inside the bearings and the gear reduction area (clutch mechanism, pinion shaft, gears, bearings). Also the brushes and the armature both wear
from use.

None of those parts are replaced with the kits above and nothing internally is cleaned or re-greased. Then there's corrosion of the case and long bolts,
large O-rings for the case that are not in the kit, a large rubber grommet/boot that comes apart with age, etc, etc

So replacing the contacts and plunger may get more years out of the original starter but that isn't the same as a remanufactured Toyota starter where all worn parts would be replaced with new DENSO-Toyota parts.