Mystery Starting Enigma (1 Viewer)

[BillWright]

My FJ Cruiser has developed an alarming intermittent starting failure.
It is a manual, a 6 speed. I mention this because it may (or may not) be pertinent.
I've recently recovered Bonnie from three years foster custody in NC. She was doing some Burning Man work and being cared for by a friend while I was basking in the Adriatic mostly.
So I guess she's been back for a month. During that time I have had three instances of not turning over when I tried to start it.
First time after I left it for a while it cranked. Meanwhile I replaced a the old battery.
Another time I stalled it backing up and it wouldn't restart. The next day I went over and stirred the gears a bit* and she cranked right up.
Last night it wouldn't start. Stirring the gears didn't work.
This morning more gear stirring and tried and she started right up.
* So I'm thinking some interlock might be out of adjustment or faulty. In my absence the FJ got a new clutch and some transfer case work.
. . . Or possibly some relay in the starter circuit is intermittently failing
I HATE Intermittent Problems
Any ideas, experience or consolation would be appreciated.

 

[Krondor]

When you turn the key, do you hear the starter relay click every time? It is a soft audible noise right before the starter activates. If the relay is working, you may need new starter contacts. I had a similar problem with my tundra recently. The contacts were eroded and that was the cause of my intermittent issues. How many miles are on your cruiser?

 

[3pits]

Same here on my 80, iirc it was like $8 for the parts from my local starter shop.

That said I'd test voltage to bendix and from battery to starter, next time it happens, if that's okay it's the contacts,

if not okay:

check ground connections from engine/transmission to body etc..they may have not reinstalled them when clutch was done...

check the sensor That tells the engine you pressed the clutch pedal in..

Lastly I'd check the ignition switch..bc it's hard to get to.

 

[BillWright]

When you turn the key, do you hear the starter relay click every time? It is a soft audible noise right before the starter activates. If the relay is working, you may need new starter contacts. I had a similar problem with my tundra recently. The contacts were eroded and that was the cause of my intermittent issues. How many miles are on your cruiser?

Haven't noticed the relay either way. I'll listen for it. I've tried it repeatedly today always successful so far.
Do you mean starter contacts inside the starter?
80800 miles.

 

[BillWright]

Same here on my 80, iirc it was like $8 for the parts from my local starter shop.

That said I'd test voltage to bendix and from battery to starter, next time it happens, if that's okay it's the contacts,

if not okay:

check ground connections from engine/transmission to body etc..they may have not reinstalled them when clutch was done...

check the sensor That tells the engine you pressed the clutch pedal in..

Lastly I'd check the ignition switch..bc it's hard to get to.

What Sensor? Where is it?
I'll need to book some lift space at Trollhole's to pull the starter and etc. We're HOA forbidden to use the compound for DIY mech work.

Good to see you again BTW. You still in Royston?

 

[3pits]

Iirc On my ranger it was up under the dash like the brake light actuator...it actually looks like a nrake light sensor, so, im not sure where it is on the fj. It prevents starting while in gear/clutch pedal not depressed.

Starter is super easy, well, an fj62/fzj80 one is..

Thanks, good to be connected to the club again.

I spend 90% of my time in atlanta.. I actually saw digdug on i20 eastbound a few weeks or months ago.. I still own my warehouse in Royston and my gf is there too...if ya need assistance in ATL lmk. I've got a pretty flat driveway space, I'm in grove park.