2010 T4R - Blown Stop light fuse, won't start, shorted Tail Light
My 2010 Limited 4Runner would not start the other day. When I hit the brakes and pushed the start button it would not turn green (stayed orange), would not start, and no response. No clicking, no noises, and the instruments remained dark.
When I hit the start button a second time, all accessories were enabled and functioned fine.
I suspected dead batteries, bad FOB's, one of the safety interlocks, stoplight switch, and several other things, but all were dead ends.
The Short story: I found out how to Bypass the Lockouts and get it started, and then finally traced it back to a shorted brake light wire.
Also confusing is that when I started it in Bypass Mode, the anti skid light and ABS lights were on.
What did I do first:
- Checked the main Battery Voltages, recharged, and confirmed 12.7v, and lots of starting power available.
- tried both FOB's, tried holding them close to the start button, checked their batteries, confirmed that they would open and close the remote locks from +20feet away.. etc.. no FOB problem's
By chance I read somewhere about a possible safety interlock start bypass No explanations, no descriptions on how to, but by luck I found out it is real, and here is how that works:
- Touch / Hit the start button once with no foot on the Brakes (normal start)
- Hit the start button a second time (accessory mode) but do not release, and hold it down for 15-20 Seconds
- The T4R's will now start and bypass all the electronic safety lockouts.
- You can not shift out of park at this point because the shift lock is still engaged
- Pry the small plug out located in the console beside the shift lever to access the manual override, insert a small key or screwdriver and push the button, shift to reverse, drive etc as per normal.
NOTE - You can now drive the car, but what ever is wrong electrically is still there, you have just overridden many of the safety Features, and this is an Emergency Procedure Only! It also helps trouble shooting as you can start you car!!!!
Now on to the Electrical Problem!
I checked all the fuses located in the panel under the dashboard. No Faults were found. I checked all the fuses in the engine compartment and found the 10 amp Stop Fuse was blown. I replaced this, tried to start as normal by depressing the brakes, hitting the start button, and no start again. The fuse was blown again!
I was now looking at some sort of short, malfunction in the ABS or other safety systems, and or the brake system.
In each step of trouble shooting I would basically replace the fuse, Test normal start conditions, and when this did not work, I would start the car using the bypass start method to confirm I had not messed anything up, and worked through each safety system disconnecting, bypassing and isolating them.
I suspected the brake Switch because of the lockout situation and this is the first thing in the circuit downstream of the fuse so I disconnected it, checked, tested various situations of unplugged, and finally replaced this as it was only ~ $40 from the local Parts store.
Same thing, and each time I tried a normal start sequence, I had same conditions, no start, no green light on the start button, the fuse was blown again, but it would start in Bypass.
At this point, I bought 20 x 10 amp fuses to start isolating the problem.
I suspected the STOP Relay in the engine compartment fuse box. Tested, checked, tried several configurations, and determined it was working ok.
I disconnected the wire harness connections to the ABS ECU located in the engine compartment, drivers side, on the side of the brake system, Replaced the fuse, no start, same conditions.
Next was the shift interlock - I removed the center console by screwing off the shifter handle, then puling up on the side of the silver console cover to pop it off (about 2 minutes of work, and thank you Utube for how to do that one).
This exposed the wires for the shift interlocks, parking brake connects etc located under the consol. I disconnected the interlock wires for the shift lever suspecting a possible short there. Went through all the same things, and still blowing the fuses.
So now I am down to brake lights and systems.
I did not suspect them first because each time I tried to start the car and hit the start button I was blowing the fuse. I thought one of the interlocks was shorting when it was powering up and they also receive power signals from the stop circuit.
I reality, what was happening is that in order to start the car, you must put your foot on the brakes. With each new fuse, each time I tried to start, The first thing is power was being applied to the brake lights, and shorting out.
Easily verified, I replaced the fuse, touched the brakes, and fuse was blown. I did not have to try starting the car, it was just a read herring that when that fuse blows, you can not start the car. it had nothing to do with any of the safety systems.
So I disconnect the tail light harness from the left and right side in the rear of the car. Touch the brake pedal and the fuse did not blow.
One by one, plug in the left brake lights - OK, Plug in the right Tail Lights fuse blown... Problem isolated in the right Tail Light assembly
With my right tail light assembly disconnected, and a new fuse in place, I could "normally start the car" and everything else worked fine.
After removing and disassembly of the tail light assembly I found that one of the wires running to the brake bulb had been pinched between the mounting screws, and the frame. This must have happened when I had some body repairs done, they replaced it, and it was just marginal for it to last for 6 months while I drove around all winter.
I could see the pinched wires, and exposed copper that was grounding out I small piece of shrink wrap, some heat, and "proper reassembly so no chance the wires got pinched and after 2 days of head banging... I now have a car that starts normally, and working brake lights!
PS - I cant even imaging what the Dealership might have done or charged.