RTH - Starter Stuck running

[Otamiway]

Drove around all day in DE without any issues. Many start and stops. Packed up about to head to NY and started up. Couple dash light stayed on after start and I hear the starter still spinning. Turn off ignition and the starter still kept going. Had to shut off 2nd battery and disconnect main battery.

Any quick fix to limp home??

 

[86tuning]

the starter plunger has stuck/welded itself to the contacts. IMO remove the starter and repair or replace it. If it was stuck for more than a few minutes, I would replace it.

It's held in with 3 screws, one for the b+ (12v power!) wire, two to hold it in place. You can take it out with a 12mm and 14mm sockets in 20 minutes or less. Disconnect the battery first.

After removal, you can take the endcap off (that's held on with 3 screws) and unstick the plunger. Starter contacts are only a few bucks from most parts stores.

 

[OGBeno]

The starter bolts require 17mm sockets.

 

[86tuning]

The starter bolts require 17mm sockets.

Haha, my memory is almost as bad as, er, I forget what it's almost as bad as...

 

[Otamiway]

thanks Brian and Onur..

Any problem if I start the truck and remove the starter just to get home??

 

[ppc]

Get underneath and give the starter a few good hard smacks with a hammer, big wrench, tire iron etc. That should free up the plunger. Start the engine again and it if sticks again smack it some more. If it stops sticking I would think your good to get home. Fix ASAP as the condition will get worse in a short time.

 

[Otamiway]

Thanks Phil, I slap the *hit out of it and it didnt do anything.

Because is was midnight and my wife had to get to work, I decided to disconnect the starter power cable and head home.

Lucky for me, when installed my dual battery kit, I went with all military terminals which allowed me to only discconnect the starter cable.

I stopped at every rest stop up the Jersey Tpke to check the temp of the starter... All was good... no melt down..

I made it home 4hrs later.

This morning, the starter is back to normal. It comes out right after work this evening.

Thanks again for the responses
Stu

 

[Otamiway]

The change

Took the original starter out last night. Picking up a new one from a locl Toyo dealer.

Used a long extention & a 12mm to get to the main cable

Turned the wheel full right and slid under wheel well.

Used a 17mm wrench to get to top bolt. A long 3/8 ratchet with a swivel in the handle to get to the bottom bolt.

Gently tap after bolts were out and it came out.. 40mins

 

[Otamiway]

Got a 2.2kw Replacement

I got home Fri night to a pleasant surprise. My 2.2kw from SD showed up. Very impressive unit and way cleaner than the one from my 97.

I should have the rebuild parts from Beno at American Toyota NM on monday

 

[Kernal]

Otamiway: what parts are you replacing on the 2.2kW, just plunger and contacts or more (bearings, brushes,---)??

 

[Otamiway]

Otamiway: what parts are you replacing on the 2.2kW, just plunger and contacts or more (bearings, brushes,---)??

Kernal, Just the contacts and the plunger... I should have a ll the parts today. i will post some pictures.

 

[Kernal]

I have a 2.2kW also, got just the contacts as the plunger cleaned up nicely. I've been toying with the idea of pulling it all apart and checking the bearings and brushes, not sure what parts are still available.

 

[Otamiway]

Kernal, I am going to keep an eye out for another 2.2kw to do a more comprehensive rebuild.. I am not sure what parts are still available for it..

 

[AllenTenT]

I had this issue, took the starter apart found rough spots on the plunger sanded it all smooth put it back together and it was fine, I ordered the new contacts and plunger but its been 3 years now and hasnt done it again and the new parts go everywhere with me.

 

[Otamiway]

I had this issue, took the starter apart found rough spots on the plunger sanded it all smooth put it back together and it was fine, I ordered the new contacts and plunger but its been 3 years now and hasnt done it again and the new parts go everywhere with me.

Good to know that once I rebuild the 2.2kw it will last..

 

[Otamiway]

The Parts

Thanks to Beno.. I am ready to rebuild..

 

[Otamiway]

Quick update.. New to me 2.2kw in and working like a charm. Rebuild slated for next month..

 

[Otamiway]

So a little over 4 years later my new to me 2.2 starter started to act up. Good thing I had my rebuild kit handy....

 

[Otamiway]

It took longer to get the starter out than to rebuild it

 

[Otamiway]

Last picture if the most important part of build.. Making sure contact are level...