Look what happened to my starter!

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Joined
Sep 10, 2021
Threads
10
Messages
32
Location
DC
Last week my LC stopped starting out of the blue, and it definitely took me by surprise. Like, it cranked relatively slow compared to the rapid fire cranks I hear from newer cars, but it would still start reliably every time under 3 seconds ever since I bought it a month ago. I thought it sounded just fine anyhow. Then that day it died and I felt like there was no warning, except maybe the start immediately before that which was maybe a little extra sluggish.

At first I tried to jump it, didn't work. Battery measured 12.4V too, so it definitely wasn't the problem. When holding the key in ignition, all I heard was a faint whirring noise, possibly the starter motor, but didn't hear anything else, -- no clicking of solenoid. Was pretty sure the starter was the problem at that point, not fuel, because it didn't even crank.

I, with the help of another monkey, got to work tearing it out. Here's what I found:

fked starter.jpg


The pinion gear was completely stuck. Couldn't rotate it at all. That topmost ball bearing there in the picture was jamming it in place. Littered around the starter under the intake manifold were those ball bearings in my hand. Crazy to think they were just getting spat out by the starter over time.

Replaced it with a Denso reman starter (#2800320), and a few other parts along the way while I was in there. Took us 10 hours and a good deal of frustration. But now, my LC starts like a dream. It cranks strong and fires up fast :)

Anyone else have this problem before? Definitely was surprised to see this when we opened it up. I was expecting maybe the motor/solenoid/contacts/anything else before this. The gear teeth don't even look particularly worn. Flywheel gear teeth were completely fine too, unlike one starter replacement video I once saw that had a bed of metal shavings in the flywheel cavity. I did notice though, before I replaced it, that if I held the key even a split second too long in the ignition start position after the engine fires up, you would hear the most horrible, painful grinding noise. I assumed it was normal in old cars without a shutoff switch. But now, with the new starter, the grinding from holding the key too long is much, much softer, barely there even. Is it possible that my car led a life of poor key usage for the last 230k miles, causing this over time? 🤔
 
Not a bearing failure, but starter failure yes.
 
Take it apart! I want to see what broke inside. More importantly, was it a Toyota Denso starter or aftermarket junk?
 
I concur with taking it apart. There's not much going on in there, and the bearings, seals, and electrical components are available for purchase. I'm very happy to have a starter that I rebuilt, and I would encourage you to at least take it apart to see how it works. It would be interesting to see why it spit out bearings! Alternatively, if you're going to throw it away, I will pay shipping to me so I can take it apart and see what failed, and I'll pass the core along to someone else who needs it for free.
 
In all my years of turning wrenches for a living never seen a starter came apart like that, my 03 T4R with 2UZ is pushing 291k and I think it still got the original starter and it worries me that it will just take a crap in the middle of nowhere.
BTW how many banana's did you pay the other monkey? J/K:lol::lol:
 
Also, if you live in Tacoma then why is the pinion gear so rusty? That kinda looks like there was significant moisture in the bell housing? Possibly from a salty and/or humid environment? Interesting for sure.
 
Take it apart! I want to see what broke inside. More importantly, was it a Toyota Denso starter or aftermarket junk?
I believe it was the original Toyota Denso starter. Although, the sticker is green, and all LC starters I've seen (~4 lol) had red stickers. Wondering what's up there.

old starter.jpg

I concur with taking it apart. There's not much going on in there, and the bearings, seals, and electrical components are available for purchase. I'm very happy to have a starter that I rebuilt, and I would encourage you to at least take it apart to see how it works. It would be interesting to see why it spit out bearings! Alternatively, if you're going to throw it away, I will pay shipping to me so I can take it apart and see what failed, and I'll pass the core along to someone else who needs it for free.

I will take it apart sometime in the coming week, and will update this thread with findings! If I end up too lazy to do it, you can definitely have it.

In all my years of turning wrenches for a living never seen a starter came apart like that, my 03 T4R with 2UZ is pushing 291k and I think it still got the original starter and it worries me that it will just take a crap in the middle of nowhere.
BTW how many banana's did you pay the other monkey? J/K:lol::lol:

Hahaha zero bananas ;) I am glad it went out now rather than later if it was going to tbh. I was going to drive 3000 miles in 2 weeks across the country! Good luck with yours, 291k is amazing for original starter.

---------------------------------

One thing I didn't mention, which is why I'm so concerned with holding the key too long, is that literally on my starter's last day of life, it was at a Toyota dealership for a power steering flush. Oh god, it was horrible. The service line was long af and completely packed with cars, mostly corollas. Every time this long line moved forward a car, the technician would start up the next car and move it forward a few feet. Every ******* time he went in my LC, he held the key in the start position for several seconds longer after the engine fired. I could hear the grinding from the parking lot, it was LOUD. Felt like hours of destroying my gears. The last start it ever gave me was the one that got me home from the dealership..

I was really about to walk in and ask the guy to please be nicer to my poor LC. I didn't though. I imagine techs don't like hearing about how to operate a car when it's their job, especially from a young woman.
 
@iliveinmylc I think that is original since the reman unit if I'm not mistaken would say Remanufactured. Not even a cold beer for the helper monkey? :cheers:
BTW the people that move cars are lot boy/girl or the service writer most mechanics don't go out in the service drive unless they have to, they are too busy trying to upsell more work. :rofl:
 
Also, if you live in Tacoma then why is the pinion gear so rusty? That kinda looks like there was significant moisture in the bell housing? Possibly from a salty and/or humid environment? Interesting for sure.
The rust is a really good point. Didn't even think about that. This was a WA car it's whole life. It does have rust in specific areas though. When I got it the tow hitch bar was completely rusted and flaking off. The exhaust system from the cat-back literally fell apart. Literally, as in I don't have my exhaust pipe anymore (part #1740550030).. it fell off in a parking lot one day LOL). The rest of the car is ok, the underside has minimal rust, and all of the surface variety at that, except the big muffler piece which also seems to be on its way to falling off in the next parking lot. The rear brake calipers are pretty rusty. That's why I think it was used to maybe tow and drop boats into (salty) water.

Not sure why it would have affected the starter pinion gear though. I will say there was no rust elsewhere where it was sitting.
 
I suspect the bearing failed and blew the race out on the flywheel side. There's no clip there, just the bearing race, I think. Here's my original starter. Green sticker.

Annoying the lot techs were a little careless with the starter time, but unless they revved the engine with starter still engaged I think that's unlikely to have been the cause. That bearing should handle idle RPMs just fine briefly.

Weird failure. Thanks for sharing!

PXL_20210929_053348364.MP.jpg


PXL_20210929_053327474.MP.jpg
 
I've seen this before. It was an 98 w/250K. Owner had aftermarket remote start installed. Vehicle had starting issues for years while using remote, sometimes starting first try others not. It was likely, remote (user) would start while already running and/or starter would hang (not disengage) once started, at times. Likely damaging drive, which than would not always align with flex plate, damaging more and more on each start. I suppose the snap ring itself could have come loose and that was beginning of the failure cascade. But remote start IMHO likely culprit.

Starter old (1).JPG

Starter old (2).JPG

Starter old.JPG


Ball bearing fall into valley of block, as starter pulled from block. There may be a ball or two sitting in bellhousing inspection plate.
 
I did notice though, before I replaced it, that if I held the key even a split second too long in the ignition start position after the engine fires up, you would hear the most horrible, painful grinding noise. I assumed it was normal in old cars without a shutoff switch.

^^^^^

That would be the bendix not retracting....because of the rust. It was remaining engaged to the flywheel ring gear for periods of time. Eventually... that caused the seal on the bearing to become dislodged. Without the seal in place....the lubricating grease was lost. That bearing is drier than the bottom of a Camels Foot.

Dry Bearing.jpg
 
^^^^^

That would be the bendix not retracting....because of the rust. It was remaining engaged to the flywheel ring gear for periods of time. Eventually... that caused the seal on the bearing to become dislodged. Without the seal in place....the lubricating grease was lost. That bearing is drier than the bottom of a Camels Foot.

This makes a lot of sense. Thanks a lot for the insight! I am surprised at how not worn the pinion gears are if it was indeed failing to disengage.

Now I'm curious if I can literally just hit it with some evaporust and replace and regrease the bearings and have it work again.

After dealing with rust on specific parts of this LC, I am starting to figure out which metal parts are crappier than others. My tow bar was falling apart, but the part of the frame it was bolted on to had no rust, for example. How the pinion gear rusts like this while the rest of the starter is basically rust free is annoying. I wonder if they could have made this part better some how, or if, now that we know this type of failure exists, we should put some sort of treatment on starters before they go in cruiser in rust belt areas. Hmm
 

Users who are viewing this thread

Back
Top Bottom