Intermittent Starter No-Crank

[Lowside]

1994 FZJ80, 190k miles

Hi Cruiserheads, I’m having a frustrating problem that I need to ask for help with. Intermittently I get no crank of the starter when I turn the key. I get a click that sounds like it's coming from the starter area and a very low humming sound but the starter does not turn. Voltage at the battery is 12.2 volts and drops to 11.8 with the key turned to the start position (while the problem is occurring). This began happening about 6 months ago so I pulled the starter and replaced the contacts and plunger. The problem went away so I thought it was fixed. But in the last two weeks it’s happened again three times. Every time the problem fixed itself when I let the truck sit for about 3 hours.

Also, there used to be a guy here who worked in the parts dept of a Toyota dealer and gave good prices for parts. Is that guy still around? I’ve lost his contact info.

Thanks for any help!

Ted - Denver

 

[Lka1988]

You're looking for cruiserdan. He is the Parts Shaman you speak of.

Sorry, but that's about all the help I can give you.

 

[mtullis]

Me 2

I'm having the same problem some times it will start and some times it will just click when you turn the key to start. If i keep working it will start just have to keep turn the key to start and back. HELP

 

[MoJ]

Might give this a read

https://forum.ih8mud.com/showthread.php?t=125974&highlight=ignition+switch

That above thread turned into this one

https://forum.ih8mud.com/showthread.php?t=138420&page=2

skip to the second link if you're impatient.

 

[cooldry]

Finally, someone with the same EXACT problem I have. I've been trying to figure this out for the last several months. Just like you, if I let the LC sit for about 3 hours, it starts up again. 3 seems to be the magic number. Just to let you know, one thing that does work every time is if you jump the LC. For some reason, that gets it going again.

 

[cooldry]

The two parts that really confuses me is, why does it start if you jump it. And why the 3 hour wait. Doesn't matter if I drive for a long distance or just for 20 minutes. It's always around 3 hours.

 

[MoJ]

The two parts that really confuses me is, why does it start if you jump it. And why the 3 hour wait.

battery..............have you tested it?

 

[cooldry]

battery..............have you tested it?

That's one of the first things I did. I even went and got a new battery, hooked it up, wouldn't start. Put the old battery back in and tried jumping from new battery and wouldn't start. Only way is to jump from another vehicle. Then it starts. Go figure.

 

[Brian Macgyver]

Nippon starters are all the same. You can put contacts in, but if you don't do it right the problem comes back. The trick is to make sure that the contact is installed straight. The contact must be pushed against the housing and then tighten the brass bolt into place. If you press the bolt into the contact and then install it, the contact will be tilted, resulting in a small contact area that will soon burn out. I also always spin the plunger with a drill and polish the contact circle to remove any burrs or arc marks. I lube the plunger with moly grease to keep it from sticking.
You can replace one or both contacts and still not have a repair. The copper circle on the plunger must still make contact. If it is arced to the point that it does not connect well, it will still be intermittent. Make sure that all contact surfaces are smooth and connect well.

 

[roncruiser]

Believe you me, I've had many no starts in my time. Based on experience, I'd say replace your starter. The solenoid is going out. Read this:
https://forum.ih8mud.com/showpost.php?p=2565611&postcount=30

Those two ridiculously long threads listed above were started by me. Save yourself some heartache and take my advice. Unless you're a glutton for punishment, replace the solenoid (starter), and be done with it.

 

[cooldry]

Believe you me, I've had many no starts in my time. Based on experience, I'd say replace your starter. The solenoid is going out. Read this:
https://forum.ih8mud.com/showpost.php?p=2565611&postcount=30

Those two ridiculously long threads listed above were started by me. Save yourself some heartache and take my advice. Unless you're a glutton for punishment, replace the solenoid (starter), and be done with it.

I read through all of your previous posts when I first had this problem. Man did I feel for you. Not to sound mean, but it made me feel better knowing I wasn't alone. Seemed like you were having a much tougher time than me. I guess I'll be replacing the starter this weekend. I'll post the results in a few weeks when I get a chance to really test it.

 

[Lowside]

Ahhh! I wasn’t able to check this thread last night and didn’t realize how many responses there were. Thanks to all for your helpful suggestions! I have some info to add to the discussion. I spoke today to a friend’s brother who’s a 20 year master certified Toyota Tech. He said that he’s seen this exact problem numerous times and it’s damn near always the starter contacts. When I told him I’d just replaced the contacts he immediately told me the exact same things Brian Macgyver said in this thread. That the placement of the contacts must be correct just as described by Macgyver. He said he gets the contacts placed just right then tightens the bolts that hold the contacts in place very tight. So, I’m going to try that this weekend and hopefully that’ll fix it. If not I’ll probably go with a reman unit from CDan.

Ted - Denver