Electrical issues (starter?)

Joined
Oct 6, 2021
Messages
14
Location
Virgina USA
I Replaced the original battery cables with Hudd expo battery cable kit and new battery terminals, the car wont turn on 9/10 when it doesn’t turn on all the lights work and just a click coming from the starter… tested the voltage with a meter from the positive to the starter while turning the key and got around 12v. Took the starter out and took it to get tested and it tested fine. Bought a solenoid repair kit from wits end just incase but im left clueless on what to do. Battery is a year old and fusible link is 3 months old.
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ppc

M Go Blue
Joined
Aug 18, 2003
Messages
3,796
Location
Nashville, TN
Those photos show the starter contacts are not installed properly. There should be even wear across the entire radius of each contact. The photo shows the top contact wear on the right corner only. The plunger shows a lot of wear and may have not been replaced if this was a remanufactured starter. The excessive wear on the plunger could be caused by the poor/small contact patch.

Replace the contacts and plunger with new parts installed properly (square to each other) and your starting problems will go away.
 
Joined
Oct 6, 2021
Messages
14
Location
Virgina USA
Those photos show the starter contacts are not installed properly. There should be even wear across the entire radius of each contact. The photo shows the top contact wear on the right corner only. The plunger shows a lot of wear and may have not been replaced if this was a remanufactured starter. The excessive wear on the plunger could be caused by the poor/small contact patch.

Replace the contacts and plunger with new parts installed properly (square to each other) and your starting problems will go away.
Ill try this when the new contacts come in on Friday. Not sure if this is an original starter or not but I didn’t have these issues before i replaced the batter cables and terminals
 

ppc

M Go Blue
Joined
Aug 18, 2003
Messages
3,796
Location
Nashville, TN
May be an original starter but those contacts have recently been replaced incorrectly. That is obvious. There are some good threads with pictures to show how to properly make the repair as well as showing normal wear patterns. Toyota starters are notorious for needing contact/plunger repairs in the 100,000 to 150,000 intervals.
 

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