My 4Runner has been having some trouble starting lately. I would stick the key in the ignition, turn, ...nothing. I would try again a few times and every now and then it would try to turn over but would after about half of a "start". Eventually I would be able to get it to start after trying and trying.

With the car being 15 years old with over 230k miles, I thought it might be that the key was worn down, so I started using my spare key that is less worn...same problems. Also, the positive battery cable was pretty loose so I would usually jiggle that to help get a better connection. With the weather getting colder, I thought the battery terminal might have shrunk more than the cable and it was just enough to give me fits. Well, this morning, I tightened up the battery cable (although it could be a little dirty) and I still have the same problem.

Any ideas as to what might be causing the problem? Think it might be something with the starter or some relay-something-or-other?

I appreciate your help. Thanks!

Starter contacts

+1 for the replacing of the starter contacts.

First of all, let me apologize for making another "starter contacts" thread. Apparently there are several. I'm swamped at work, but this is a critical issue since I need to be able to get to/from work until I can repair the problem. So I thought it would be easier/faster to get some opinions going before I had an opportunity to really start researching.

I looked into some different starter rebuild kits. There's this Dorman 02349 that I found on RockAuto and Amazon for about $19. I also found this rebuild kit that includes contacts and a plunger (link) for $12.

So, should I buy a new plunger or just clean up the existing one?

Usually it's just one of the contacts that needed replacing--my case. Bit I didn't know that until I got in there, so I swapped both contacts and plunger using the Victory Lap kit from Amazon. I'd link it, but my manual uses a different starter(1.2kw), and thus plunger, than the autos.

So for $14 it was worth it to me to have all the parts rather than get surprised while the truck was apart.

I just replaced the starter contacts on my '99 4Runner this weekend. From what you're describing, that definitely sounds like the issue. There are multiple 'starter contacts' threads that serve as great resources - just search for them. They also contain the OEM kit part #s that you'll need if you go the OEM route. I've read several posts where people end up only replacing one of the contacts. As was in my case, only one contact was worn, but I figure if you go through the trouble of replacing one, you might as well replace the other and the plunger all together; the parts are cheap enough. IMHO. Good luck.

I saw the Victory Lap version. I'm thinking the link I have above with the plunger and the contacts for $12 has the two contacts that I would need and it has a Denso plunger. I guess my question at this point is if I also need the other stuff (bolts, nuts, washers, etc) that are in the Dorman link, or can I just reuse the existing stuff?

You can use the existing hardware (assuming there's nothing worn or broken). There are a couple plastic components and some o-rings that could be subject to wear. In my case, everything looked okay so I really only needed to replace the contacts themselves. I ended up swapping in some of the new components as well since I had them with the kits.

Yeah, I reused everything else. No problem there.

My 99 was doing the same thing back in April and it was the starter contacts. I used the Victory Lap kit (ND-34SOL) which was $11.73 on Amazon. I also ordered the Dorman kit you mention (02349) for all the extra hardware that the Victory Lap kit does not include, but ended up returning it because once I got the starter out and opened up all the hardware was in good shape. So it may just depend on the status of your equipment; may only spend $11, may need both kits for around $30.

Good news is it is simple to do. But may get on it soon. Hate for you to be out somewhere when the truck finally decides it won't start at all and get stranded.

I was able to replace the contacts and the plunger this weekend. It was a royal PITA! Took nearly 7 hours and was completely covered in grease, cuts all over the place, and sore everywhere. But it cost $12 for the parts, saving me about $400+...so ~$60/hr....meh, I guess it's probably worth it. But at least it now starts consistently, so that's good.

I ended up producing a more efficient design ...I had a few extra parts left over. I'm wondering how important these pieces are.





Piece of Paper - This thin piece of paper was on the bolt for the battery-side contact. I meant to put it back on, but misplaced it and forgot about it.

Rubber (?) boot - This thing felt like someone chewed some Wrigleys and wrapped it around the motor-side contact. I had to pull it back to remove the bolt, but it complete ripped off when I put it all back together.

O-ring (not pictured) - I found a little black o-ring. I found one on the battery-side contact bolt and thought I put it back, but it's possible it came off or maybe there was another one somewhere. It could also be from an entirely different project and I just happened to find it in the process.

Rubber nubby thing - There are two of these on the starter. One of them stayed attached. The other one came off. I think the one that came off was the one on the top side of the starter. I'm not really sure what it is or what it does...and I couldn't find the actual piece when I looked for it this morning so I just clipped this picture off the internet.

Any thoughts?

Well, no car manufacturer will arbitrarily put more parts on a vehicle than they need to. If they can safely save fractions of a penny during the assembly of the vehicle, they will. If it were me, I'd install the insulator and boot.

If the positive connector does ground to the case, you'll likely find that out at an inopportune time.