Starter contact length? (1 Viewer)

[slambson]

Tore the starter out on my 3FE this weekend as it would not start earlier this week (first time). A wack to the side of the starter got it home.

Question: How long are your contacts when they fail? FSM says standard is .513 and the limit is .332". None of mine were less than .42" in length and most a bit longer.

My failure appears to be with the 'plunger' solenoid. The pad on the one side had built up to a knob where I'm assuming it welded itself. Filed it down. Plunger contact appeared fairly decent but I don't get the best continuity across the two contacts. I have to press down just a bit to get good contact across.

So should I order a new plunger and contacts? Test benching it and it appears fine now. C'dans stuff takes about 4 days and I'd like to put it in soon.

 

[slambson]

No one measured the contacts on failure?

 

[Rich]

I don't understand your terminology. I have a '97. Perhaps my starter is different. Mine has only two starter contacts. You refer to "none" and "most" of your contacts, implying you have more than two contacts, or, are you referring to more than one occasion of failure?

You also refer to length of contact. From memory the service manual for my '97 refers to either minimum height or thickness, I don't recall which, and in any case the specs are much less than the third to half inch to which you refer in your post.

In my case, my contacts were worn beyond the specs when starting began to become erratic. I had no sticking, but did have intermittent failure of engine to turn over after starter motor first engaged the ring gear. Replacement of contacts and plunger fully corrected the problem.

I would never go to the trouble to remove a starter with failed contacts and not replace both the contacts and plunger prior to reinstalling.

 

[slambson]

Interesting

Interesting. My 3FE has 4. Two on the rear ring and two connect into the main assembly.

I was wondering how you replaced the two that have the braid to the solenoid housing. I'm assuming a crimp connection.

 

[Scamper]

To me it doesn't matter what the length or thickness is. I had about 90K on my truck when I replaced the contacts and plunger. When I pulled them out, they didn't look all that bad. But who cares. This is one of those PM items that costs you about $35 to do, vs the possibility of replacing a starter, alternator, and battery--if not the possibility of burning your truck up. Seemed like a no-brainer to me, but like most folks here, I'm probably just anal. My truck doesn't even have 120K and I'm already thinking about the next birf job after having done the last one at about 93K.

 

[IdahoDoug]

Lamb,

You've got a completely different arrangement. FZJ contacts screw directly into the starter housing - no braided connections or crimps. Also agree with the philosophy of replacing all the bits when you're in there. I've done it both ways, and the one I did not replace the plunger, I have had a couple random starter misfires.

DougM

 

[Rich]

One of two starter contacts similar to an fzj80 starter

http://www.off-road.com/toyota/tech/starter/36.jpg

 

[slambson]

Actually those pics http://www.off-road.com/toyota/tech/starter/ are what mine looks like inside the solenoid housing. Mine were in a bit better shape than his.

Anyone replaced the brushes on a 3FE? Whats the trick to replacing them?

 

[slambson]

Update.

I forgot about the pictures I took of my contacts. They were far from worn out but the plunger looks a bit sad.

Opinions?

And the new ones. The one new one was a different shape and to me appeared to be a better design.