Starting issue of a different sort... '97FJZ80

[mickyfinn]

Hey Everyone,

Been trouble free for a while now but have recently had some starting issues. Last fall had some intermittent starting and replaced the contacts and plunger which solved the problem. Several months ago something new started very intermittently. I turn the key and the motor cranks and just when it fires over it seems like the motor just hammers stopped. Release the key, try it again and it starts just fine. It will do this sometimes twice a day or once every few weeks. Hot motor, cold motor, doesn't seem to matter. Recently, it stepped up to the next level where it does this but then you turn the key, motor hammers, and then try it again and nothing at all happens, no click or noise. When this is happening, all the lights on the dash stay lit up like you are still cranking it over. After 10 seconds or so and turning the key several times to start then off completely, it will fire over fine.

My first guess is that it seems like the bendix is stuck out and the motor is stalled by the torque of the starter. It's a pretty violent, abrupt sound. I did clean and lube it when I replaced the contacts and it all looked fine. Are there alignment issues when reinstalling the starter? Maybe worn bushings? Another thought now that it is doing the new issue is maybe in the ignition switch or plunger. It does seem that when I do turn the key on and off when it's in the stuck position, nothing happens but occasionally it will turn over if I turn the key hard fully to the end of the start position.

Any thoughts??

Thanks,
Evan

'97 FJZ80
@170000 miles

 

[gisham]

Seems like people battle with starter issues all the time on these 80's- Would just buying a brand new starter from Toyota solve the issue? Seems like it would be a less stressful route than replacing this and that and still running into issues-

 

[100 TD]

A couple of possible problems.
A bad battery connection or starter connection or bad ground, good enough for the low current of the starter solenoid but when it closes and trys to spin the starter(high current) the poor contact fails(high voltage drop) and the solenoid opens, no more high current, closes again etc.
Have you checked your brushes?
The solenoids on starters have 2 circuits, a pull in circuit and a hold in circuit, the pull in circuit runs through the starter brushes, if you have bad/worn brushes the above can happen as well, or not engage at all.

 

[mickyfinn]

Yeah, they are a pain to pull in and out, but a $30.00 rebuild beats a new starter if it's in decent shape. That's pretty much where I'm heading now anyway. For the time and cost involved it is worth replacing at this point with a new one if it's not working right. I'm curious about whether it could be just misaligned and a quick tweak would solve it, and also if it's possibly not in the starter at all and just a problem with the ignition switch. I have experience with starters, and this problem is sort of on the fringe, but no experience with the ignition switch. Wouldn't want to change the starter and still have the problem.

I always get great input here from people who know a lot more than me about this truck!

Thanks,
Evan