What did I miss? Replaced the starter contacts and it's still not working!!!

[Isaacjohnstar]

I spent 4hrs today changing the starter contacts with new Toyota contacts.

It was 25 degrees out and my fingers are still a bit sore from twisting bolts and nuts. I've had too many hours in the office haha.

I pulled off the intake and pulled the starter out without too much trouble. The boards over the engine compartment trick was great advice!

I installed the new contacts with the instructions in the beginning of the FAQ starter contact replacement thread. My old contacts were worn. I placed the new contacts in the starter in the same order and what looked like the same alignment.

Now, I read somewhere about a wood block to use as a jig here? Or others had used a c clamp? I didn't read into why, and now I'm kicking myself.

When I re assembled everything I tried to start it and got a "click" and "hmmm" noise. No start, no turn over, no nothing. I checked all connections again and found one behind the driver side starter bolt that I forgot to plug in! Hallelujah!!!

Nope that wasn't it (F#%€ck!!!) I should have tried the stater when the manifold was off!

Spent the next half hour looking for any missed connection or bolt. Everything is plugged in and bolted up.

I also installed a brand new battery at the time of the repair. The connections are tight and the door ding and lights come on when I turn the key.

Any ideas? Did I miss a step in the contact repair? Could the starter be bad in a way that contacts can't repair?

I usually don't have much frustration with non completed repairs, but with the cold and limited time this one has me wound up.

 

[Isaacjohnstar]

Update:

I just found a FSM screen shot that specs what the wooden block is for. I will post it up. I under stand now looking at it what some are using a C clamp for.

I also checked the EFI relay under the hood. I tapped and tried to start it. Nothing. I removed it and jumped the connections with jumper wires, then tried to start it. Nothing.

I guess I will pull the intake back off and dig into the starter unless someone has a better idea?

 

[Isaacjohnstar]

Here are photos of the contacts and the fsm

 

[Isaacjohnstar]

After reading and re-reading every thread I can find on starters and starter issues, I have ordered a new Napa starter.

Some how I messed up the starter contact replacement procedure. I will know more when I pull it apart tomorrow. If the contacts are not fubar I will be offering them up at a steep discount to who ever wants them.

The Napa starter is all new and comes with a life time warranty. It cost $105. Toyota does not supply a new starter, so I am hoping this will outlast the rebuilt OEM replacement.

Ill update with more photos tomorrow.

 

[Isaacjohnstar]

I installed a new napa starter yesterday and it works great!

It took me 2 hrs and 40 minutes to remove everything, install the new starter, an reinstall everything. Practice saves a bit of time. I am not completely sure what I did wrong with the contacts, but if I did it again I would just get a new starter.

The best tip I learned from Mud were to place towels and then boards over the engine from fender to fender. I adjusted there position depending on what I was working on.

The Intel about the driver side starter bolt was good as well. I disconnected the driver side wire connector and bent the bracket holding it and another connector up to give me a straight shot to the bolt with a short extension and a 14mm socket.

I'll post some more photos

 

[Isaacjohnstar]

The boards over the engine compartment. This made the job much easier and my patience much higher

 

[Isaacjohnstar]

The location of the driver side starter bolt with my short extension and socket on it. You can also see the connector I removed.

 

[fireball]

Glad you got it figured out! I read your initial troubles but didn't have anything useful to add as when my starter went out I just replaced it with a reman'd Toyota unit.

Hope you have good luck with the Napa unit.

 

[Isaacjohnstar]

I included a photo of the location of the (2) 12mm bolts that connect the wiring harness to the starter.

One last thing I found was helpful. When removing the intake manifold by my self it is hard to lift it off of the four studs. I lifted the front off the front two studs and placed to scraps of 1x4 wood under it. Then I could lift the entire intake out without it binding on the studs.

 

[Isaacjohnstar]

Thanks Fireball! It wasn't so bad with the exception of doing it twice haha

 

[parnoren]

I just did mine last week with 168,000 miles on the clock, and I also changed the plunger since was all corroded.Did you change your plunger? Maybe it was corroded as well.

 

[Isaacjohnstar]

I did change the plunger with a new Toyota unit. I did not do any bench testing before install and I think that is where I failed. I'm not sure if my install of the contacts and plunger were wrong or if the rest of the starter failed.

I am giving away the contacts if anyone wants them? If not I'll not bother to take them out of the core when I return it.

 

[LandCruiserPhil]

I did change the plunger with a new Toyota unit. I did not do any bench testing before install and I think that is where I failed. I'm not sure if my install of the contacts and plunger were wrong or if the rest of the starter failed.

I am giving away the contacts if anyone wants them? If not I'll not bother to take them out of the core when I return it.

Sorry to hear your troubles but glad you are up and running. Bench testing is something I always do having been through the same problem years ago. The positive is the lesson learn will never be an issue ever again.