Installing new starter contacts

[Rookie2]

I was going through the procedure in the 97 FSM for this, and it's got a section in there on "Tightening Terminal Nut" by using a wooden block and a hand press to put a very specific amount of pressure on the contacts before tightening them down. The write-up on off-road.com doesn't mention any of this. Have you all typically been following this part of the procedure in the FSM, to set the contacts?

Thanks,
Rookie2

 

[Riley]

I forgot to do this but I would if I was you. Maybe I got lucky or maybe it will come back to haunt me.

If you don't have a press, rig up something as best you can to put pressure there before tightening. Maybe a vise and some chunks of wood?

The goal to get everything straight so the plunger makes a sqaure contact. Check the write up on Slee's site, maybe there's another method posted there.

 

[Terrax]

Starter contacts replacement

I"ve done both starters in my 94 and 96 80's without using that method and they are fine. My 94 FSM didn't specify that step. I would worrry about as long you tighten it well.

 

[RWD]

I used a wooden hammer handle to apply pressure while I tightened the bolts. If you don't there is a chance that the contacts will spin slightly and not sit square to the plunger thing.

 

[Scamper]

You should use a block 'o wood (acronymn for Toyota Special Service Tool) or whatever to simply apply lots of pressure to both contacts at once while tightening so that they seat level with one another--this is so the plunger makes contact with them simultaneously. I think this is the way most guys do it here.

I too thought about using a vise to apply the pressure, but I don't have a vise large enought to fit all that, and with my luck, I'd probably apply too much pressure and crush the dman thing. Also don't happen to have a press. Maybe I need more shop tools

Mine's been running just fine since doing it this way, so I wouldn't worry.

Tom

 

[cruiserdan]

Yup, use a blocko wood and one of those sliding-bar type clamps like the wood butchers use on Sunday morning TV.

 

[Riley]

Yup, use a blocko wood and one of those sliding-bar type clamps like the wood butchers use on Sunday morning TV.

I forgot to do any of this and just assembled (I forgot).... I wonder if I should pull apart again?

Seems fine for 3 months or so but I wonder if I'm arc'ing the contacts and just don't know it.

 

[cruiserdan]

I forgot to do any of this and just assembled (I forgot).... I wonder if I should pull apart again?

Seems fine for 3 months or so but I wonder if I'm arc'ing the contacts and just don't know it.

I imagine that by now the contact to plunger surfaces are worn into each other and it would be a waste of time. I would not worry about trying to adjust worn contacts. If it worries you, get another set and install them. I would not go through all that labor just to check the angles.

 

[Junk]

I personally don't believe it's a necessary step.

 

[DRTDuck]

I followed the instructons on Slee's site, except for the "tightening" step. Not really on purpose, just overlooked it. Have never had any issues with it.

 

[Riley]

I followed the instructons on Slee's site, except for the "tightening" step. Not really on purpose, just overlooked it. Have never had any issues with it.

Good. That's exactly what I did, overlooked it. I'm not going to worry about it.

I’ll just bring it up with the therapist during my next session.

 

[MTNRAT]

Just finished contacts

I just finished installing new starter contacts. Not so bad except to loosen the starter mounting bolts.
The thing I really like about cruisers is they usually give you ample warning of iminent failure. The contacts acted up quite a few times and with enough time for me to order new ones. In fact they stuck at about noon today in my own driveway. I unhooked the battery, thinking those things should be here by now. (being shipped by greyhound). Oh well, figured I would just watch a little golf, and the phone rings announcing the contacts arrival.
Pick them up, go to Slees site for instructions and 1.5 hrs later...done.
The Cruiser Gods are with me.
Sean.

 

[Riley]

Those starter bolts are freaking tight!!! Agreed that that's the only hard part of the job.

 

[RWD]

I did the job a week ago and it's not so bad. I jacked the driver side front up and removed the wheel, and mid and rear skirts. The rear starter bolt is easy to reach with a 3' extension and a 17mm universal socket. The front bolt I had luck with a regular 17mm socket and 6" to 8" (can't remember) extension. If the front bolt is hard to break loose you can try a 17mm wrench with a pipe.

 

[MTNRAT]

starter bolts.

I was able to get a breaker bar with a 6" extension to just break free the front bolt. The rear was easy with a 12" extension and breaker bar. I also removed the front wheel and rear skirt flap.
Cheers,
Sean

 

[NorCalDoug]

Not that anyone would need any incentives to replacing the contacts themselves, but if anyone's curious...

I had my starter replaced by Lexus a couple weeks ago. They charged $221.92 for a remanufactured starter and $34 for labor. Cost me $0 (I'm milking the last couple thousand miles of my CPO extended warranty). The contacts were definitely worn and I had the dreaded no-start-click, but hadn't had it get stuck.
I was informed by my service consultant that they can no longer get a rebuild kit (I assume the contacts?) for the starter and had to replace the starter as a whole.

 

[doctorJ]

CruiserDan - is that true? Are the contacts going to be hard to find in the future? Or is that just a Lexus issue-I thoought they were the same? I replaced mine a few months ago, right at 100K. They were incredibly worn and getting the 2 starter bolts out was 50% of all the time spent on the job. Didn't use any wood block? I don't even remember seeing that step on Slee's site.
Anybody figure out how to retorque those starter bolts? I just wrenched as hard as I thought I did getting them off, hopeing I wasn't about to break um.
Jay

 

[NorCalDoug]

Before theres a mass panic...
I just want to make it clear that I was informed that the rebuild kit is not available to the guys I spoke with. I don't know what made up the rebuild kit...I assume the contacts would be part of the kit.

 

[Beowulf]

>> pressure to both contacts at once while tightening so that they seat level with one another <<

This is the key and you don't need to do this step if you're comfortable they are level. I did the step but it didn't seem necessary as the L-shaped pieces were a 90-degree angle and already level.

The rebuild kit is a few insulators and the copper contacts. Nothing much to it and I would be very surprised if Toyota stopped supplying the kits.

-B-

 

[cruiserdan]

No worries gents, Contacts and plungers are readily available. Many shops do not know it or in some cases do not like to do it in the event the repair does not stick.