When starting, won't turn over - sometimes... (1 Viewer)

[slaterson]

I have an '84 60 (2F), has run great for me the 6+ years I've own it. Recently, (about 2 months now), when trying to start it sometimes I can hear the relay click however it won't turn over. I thought it was a battery issue as the clock was reset and there were other indications that the battery was low. I charged the battery and things got better, however the then the same problem returned. So, I got a new battery and immediately after putting it in, on the first attempt to start it up, same thing. Nice bright lights, nice relay click when trying to start, however it wouldn't turn over.

I was unhappy, so I let it sit and tried again later (many hours). Turned the key and no turn over, so I kept trying a few times and eventually, it actually turned over and started right up. Is the starter going south on me? Something else? Looking for tips on what to check, as I can't reliably take the truck anywhere where I need to turn it off and start it back up to get it home.

 

[duncanrm]

Classic dodgy solenoid contacts in starter.. I did write a small guide for the HJ60 on this.. almost all of it is relevant to your Click No Crank fault no on your gasser:

2H - Click. No Crank

docs.google.com

 

[slaterson]

Great, thanks for the instant reply! Will give a read through and report back (probably a couple weeks before I can do much). I am able to get it started however it's far to difficult now, and that needs to change. When it's warm, it seems to be easier.

 

[yotadude520]

I would second that it's probably the starter solenoid - shameless plug but I rebuilt mine with OEM contacts & plunger before my LS swap that I'm looking to get rid of if you're interested.

For Sale - Rebuilt 2F OEM Starter for Sale - $125

Selling the starter out of my 1986 FJ60. Before converting to an LS I installed new OEM contacts & plunger and it worked great. Rebuilt the starter in May and pulled the engine in July so only was installed for 2 months. Looking to get $125 + the ride, just the rebuild kit was $80+. Will come...

forum.ih8mud.com

 

[Godwin]

Along with starter contacts check and clean battery connections, upgrade battery cables, grounds and ground connections.

 

[RustyBox]

I've got the same issue. Replaced the starter with a remanufactured one from Toyota and no change. Replaced the grounds, positive lead from battery to starter, and battery clamps; no change. Convinced myself that maybe I got a bad starter out of the box, so replaced the starter a second time; no change. All that's left is the ignition switch and the signal wire... Will troubleshoot that next once it warms up a bit here in the northeast.

 

[Godwin]

I've got the same issue. Replaced the starter with a remanufactured one from Toyota and no change. Replaced the grounds, positive lead from battery to starter, and battery clamps; no change. Convinced myself that maybe I got a bad starter out of the box, so replaced the starter a second time; no change. All that's left is the ignition switch and the signal wire... Will troubleshoot that next once it warms up a bit here in the northeast.

Adding a relay into the starter circuit usually helps. I've that these same symptoms on a 62 and 80 and adding in a relay resulted in solid starts as long as the battery, connections, and cables are good.

 

[slaterson]

a very minor bit of trying to start it this weekend, and i was able to get it to turn over after switching to "start" few times. at first, it turns over maybe 1/4 and 1/2 then stops. after a couple of those, it cranked the whole way and started up. let it run for a minute or two, shut if off, let it sit for a couple hours. tried and it turned over first time no problem. hard to say it that it's better once it's warmed up (even a little), thats what i'm hoping though.

the connection at the battery is good, i cleaned the battery terminals and connectors well. the cables are old though. i'm planning to test the starter (as mentioned by duncanrm in the first reply here) when i have a few minutes. i'm hopeful it's the starter.

 

[slaterson]

update: had a chance to test the starter this morning. unplugged the starter terminal wire and connected a long wire with the same connector (a female spade) to it. then touched the other end directly to the battery positive. it clicks about 75-80% of the times i tired, the other ~20% is turns over once and then stops turning. this has to be a bad starter.

planning to order a gear reduction starter replacement, i have read that the wiring is slightly different for those? any tips or recommendations for a different starter?

 

[OSS]

My vote is to get a Toyota remanufactured starter

 

[Godwin]

update: had a chance to test the starter this morning. unplugged the starter terminal wire and connected a long wire with the same connector (a female spade) to it. then touched the other end directly to the battery positive. it clicks about 75-80% of the times i tired, the other ~20% is turns over once and then stops turning. this has to be a bad starter.

planning to order a gear reduction starter replacement, i have read that the wiring is slightly different for those? any tips or recommendations for a different starter?

Rebuild your starter and you already have a gear reduction starter; GR starter is OEM on the 60 series.

 

[slaterson]

i ordered a re-manufactured starter. i took the old one out this morning, at least mostly out. there is a rubber cap of the main terminal that connects the starter directly to the battery. how is that removed without destroying it? its the last remaining connection to the truck, once i can get that rubber cap moved i can unbolt the cable and put the new starter in.

 

[yotadude520]

Just gently pry it up and slide it back so you can see the bolt under it.

Make sure you put it back over the bolt when you reinstall otherwise you're gonna see sparks.

 

[slaterson]

Just gently pry it up and slide it back so you can see the bolt under it.

Make sure you put it back over the bolt when you reinstall otherwise you're gonna see sparks.

this is what i ended up doing, was trying to avoid prying. the boot on mine was incerdible tight and rigid, i think due to cold/hot cycles. got it off without cracking/ripping it up, and got it push back over the terminal on the new starter. it's a bit squish and disformed though.

good news - i got the old starter out and new starter in, took about 1 hour and that was with a break to clean up and post a message here. truck cranks like a champ now, super stoked to have her back on the road. will likely replace the battery cable even though it's in good condition, i want the rubber boot at the starter to be in a little better shape.

 

[RustyBox]

Still perplexed with my situation. Replaced the connector on the signal wire to the starter thinking it was loose, made no change (cranked one time, then would just "click" no crank). Ran a jumper from the signal input on the starter to the battery and the truck starts right up. The weird thing is turning the key i always get a "click" and I can see draw on the battery based on the volt meter on the dash, but it's like it's not providing enough current to actually engage the solenoid on the starter. Remanufactured Toyota starter, so eliminated that as a variable.

 

[RustyBox]

Still perplexed with my situation. Replaced the connector on the signal wire to the starter thinking it was loose, made no change (cranked one time, then would just "click" no crank). Ran a jumper from the signal input on the starter to the battery and the truck starts right up. The weird thing is turning the key i always get a "click" and I can see draw on the battery based on the volt meter on the dash, but it's like it's not providing enough current to actually engage the solenoid on the starter. Remanufactured Toyota starter, so eliminated that as a variable.

Finally fixed, through process of elimination. After I verified the ignition switch was good, I cut into the wiring harness and ran a new signal wire to the starter. Been starting flawlessly since. Must have had a break in the wire somewhere. Never suspected this since it would always "click" when I turned the key, must have been hanging on by a thread and just not providing enough power to actuate the solenoid / relay on the starter.

 

[TLC4K2]

Nice detective work! Glad it's starting for you now!

 

[RustyBox]

Nice detective work! Glad it's starting for you now!

Feels good! But my kids are all still a little hesitant to go for a ride in "dad's truck that doesn't always start" lol. Maybe all those times we had to recruit good sumaritans to give a push for a bump start was a little embarrassing for them?? Hah

 

[TLC4K2]

I'm sure most parents can tell you that it doesn't take much to embarrass your kids. Just being 20+ years older is usually enough!

 

[jebb]

@RustyBox That fix still working? I thought my intermittent click no-start was fixed when I replaced the ignition switch but it's come back so...looking for new ideas.