Starting Issues - 1991 FJ80

[NEMESIS]

I'm having some issues getting my 1991 FJ80 to turn over. When I insert the key and attempt to start the vehicle, I just get a clunk noise and nothing happens. Sounds like the clutch pinion gear shoots out, but it doesn't crank.

Battery test good. Pulled the starter out (what a pain in the balls...) and it tested fine. The motor spins freely.

Where should I look next?

 

[jonheld]

Sure sounds like battery or starter to me. How did you test them?

THe starter contacts and plunger can be replaced with OEM parts for a few pennies.

 

[NEMESIS]

Sure sounds like battery or starter to me. How did you test them?

THe starter contacts and plunger can be replaced with OEM parts for a few pennies.

I tested the starter using the process in the FSM. Plunger moved in and out correctly and starter spun at correct load.

Any other ideas?

 

[jonheld]

Well, if the starter is making a clicking sound then the solenoid logic from the start circuit sounds like its working. Since the starter motor power comes directly from the battery, there are few possibilities here. Either the power connection to the starter is poor, the battery is weak, or the internals of the starter need replacing. If this is the original 19 year old starter then rebuilding it certainly couldn't hurt. It doesn't owe you anything anymore.

There have been a few who found the start logic side was not supplying enough voltage to the solenoid. You should check that as well.

 

[Lka1988]

Sounds like typical contact issue to me...

Couple years ago, my starter exhibited typical symptoms of failing contacts. It would not turn over, but when I first pulled it out, it worked fine (before I actually replaced anything, so the thread below is a bit irrelevant. Read through it though, and make sure you get the correct parts).

The reason it worked is because when the starter is out of the engine bay, there's no load for it to apply any real force. It takes an incredible amount of energy to start an engine, usually 200-300 amps, but when on a work bench, it pulls maybe 20 amps at the most. If there isn't a lot of contact between the, er, contacts, 200 amps is not going to get across to the other side very easily, and will generate a lot of heat in the process. The amount heat generated is able to melt the contacts, and may cause them to stick together (very bad thing). I'd pull it ASAP.

Whew.

Here's my starter woe and strife thread. Good read.

https://forum.ih8mud.com/80-series-tech/206324-rth-no-start-after-new-contacts.html