Sparks from starter/bell housing/flywheel?

[cartelcruiser]

1978 fj43

Had a new clutch installed probably less than 300 miles ago. The vehicle doesn’t get driven much, and is garage kept. Maybe 50 or so miles into it, I’d notice a high pitched squealing noise which I thought may be a throw out bearing. Guy who did the work checked it and said everything seemed good. No real issues, the truck still rolls 80 on the highway and the noise became less noticeable as it was driven more.

Today I’m driving, maybe 50 or so in 4th and the radio (aftermarket) starts to go quiet and glitch. Out of the corner of my eye I see sparks flying through the hole where my 4wd shift boot should be. This happened 3 different times. It appears to be coming from the bell housing or starter, but not sure what would cause it and also affect the electronics like a radio.

Nothing appears to be burnt or shorted out. Any idea where to start?

 

[mattressking]

Start at the battery and move backward. I don't see the battery cable on starter for....starters.

Then meter the battery for voltage, ensure all power and grounds are tight and not arcing. Your wiring doesn't look great and sparking from under the trans tunnel isn't good, so also remove the inspection cover and look at the clutch....start the truck and have someone actuate the clutch as well.

Considering it's a SA truck, I'm not confident it was slapped together with much thought, so you'll need to inspect it all or have someone local who knows what they are looking at.

 

[charliemeyer007]

I'd start at the ignition switch. When they go bad, the can randomly short out inside and trigger the starter - thus throwing sparks.

Your starter looks clocked wrong to me for some reason.

 

[cartelcruiser]

My angle on the photo isn’t the best. Confirming the cable does run to the starter, but yes this was pieced together down in SA and I’m sure the wiring could benefit from an overhaul. First issue like this I’ve had in about 7 years of ownership.

 

[cartelcruiser]

Your starter looks clocked wrong to me for some reason.

Probably is

 

[3_puppies]

Your starter looks clocked wrong to me for some reason.

that was my first thought also
is there something between the starter and bellhousing on the top stud??

either way, remove the starter and see what is going on
maybe replace the starter
need pics when it is all apart

 

[65swb45]

The starter is definitely on upside down; solenoid is always on top.

The hot lead from the battery is hidden behind the big blue boot, and is up against the block. This is the source of your sparks.

This is a 101 fail.

 

[cartelcruiser]

The starter is definitely on upside down; solenoid is always on top.

The hot lead from the battery is hidden behind the big blue boot, and is up against the block. This is the source of your sparks.

This is a 101 fail.

Wondering now if this is the source of the high pitched noise as well…I’ll have to look back through photos and see if it has always been upside down (past 7 years) or if it was flipped after work was done.

 

[65swb45]

Wondering now if this is the source of the high pitched noise as well…I’ll have to look back through photos and see if it has always been upside down (past 7 years) or if it was flipped after work was done.

The thing that I don’t understand is the degree of incompetence that it took to rebuild the starter like this. The nose cone is half shielded, to support the Bendix shaft. So the rebuilder (or the mechanic) would have had to install the cone 180 out of rotation to create this clusterf*ck.

Once you get the starter out of the bellhousing, this will make more sense to you.

(Edit) It’s possible that there is just enough eccentricity between the cone and the armature that it is putting the Bendix in a bind. THAT could cause the Bendix to whine, or worse, damage teeth on the flywheel.

 

[cartelcruiser]

The thing that I don’t understand is the degree of incompetence that it took to rebuild the starter like this. The nose cone is half shielded, to support the Bendix shaft. So the rebuilder (or the mechanic) would have had to install the cone 180 out of rotation to create this clusterf*ck.

Once you get the starter out of the bellhousing, this will make more sense to you.

(Edit) It’s possible that there is just enough eccentricity between the cone and the armature that it is putting the Bendix in a bind. THAT could cause the Bendix to whine, or worse, damage teeth on the flywheel.

I’ve replaced starters on other vehicles, I’m familiar with what you’re describing. Never dreamed I’d have to doublecheck someone’s work to this degree. The cruiser is driven so minimally that it has probably taken this long to reveal itself. Haven’t had to pop the hood until yesterday when the sparks were seen

 

[cartelcruiser]

Alright, slow work day so I came out to remove the starter and check it out. Went to rotated into the correct position, but it will not fit if I turn it to where the solenoid is upright. It creates quite a noticeable gap and of course both holes on the mount don’t line up.

It’s looking like it was placed in the way that it is because that’s the only way it would fit.

The starter has not been replaced in the seven years that I’ve owned the vehicle. Which is even more strange that it’s been driving presumably fine in the position that it’s been in up until recently.

 

[cartelcruiser]

The starter is definitely on upside down; solenoid is always on top.

The hot lead from the battery is hidden behind the big blue boot, and is up against the block. This is the source of your sparks.

This is a 101 fail.

When turned “right side up” it doesn’t fit. I understand what you’re saying, I think it’s just really ghetto rigged and time for a new starter.

 

[mrboatman]

How about a picture of the bell housing with out the starter installed

 

[cartelcruiser]

How about a picture of the bell housing with out the starter installed

 

[65swb45]

When turned “right side up” it doesn’t fit. I understand what you’re saying, I think it’s just really ghetto rigged and time for a new starter.

The good thing is that genuine starters are still readily available from Toyota.

 

[charliemeyer007]

58-82 Land Cruiser FJ40 55 60 Direct Drive Starter

Remanufactured Direct Drive Starter 58-6/82 Toyota Land Cruiser FJ40 FJ45 FJ55 FJ60 $20.00 refundable core included in price

www.fjparts.com

 

[cartelcruiser]

May also have too strong of a battery in there. I throw an AGM 850CCA in there when the previous one died last month. This was the first longer drive I’ve taken in it yesterday.

Between radio and starter issues, this may be the culprit. Regardless, I agree it’s time for a correct starter.

 

[charliemeyer007]

You cannot have too strong a battery, except when the solenoid shorts out and the starter burns up because you didn't have a wrench handy to disconnect the ground clamp on the battery,

 

[cartelcruiser]

Too high CCA actually can put strain on the electrical system in vehicles, which could cause damage to alternators and/or starters, and short in the radio. 850 may not be too high for a 40 without any upgrades, just an afterthought as I was going through everything this morning in the garage.

 

[mattressking]

Too high CCA actually can put strain on the electrical system in vehicles, which could cause damage to alternators and/or starters, and short in the radio. 850 may not be too high for a 40 without any upgrades, just an afterthought as I was going through everything this morning in the garage.

Not your problem, shouldn’t even be a consideration for failure mode. Get the starter installed correctly with a Denso reman directly purchased from Toyota (for the 1year warranty) clean terminals, ground to chassis and connect + battery and +12v switched signal and be on your way.