starting issue, possible cluch switch

[Matt_Ledbetter]

Hey Folks...

I've got a '96 5spd with over 240k miles on it...

This last week I started having an issue with starts. The first few days it was only a problem for the first start of the morning. I would turn the key and it would only "click" even though the battery was fine. Pushing the clutch in a few times (with the key turned) and it would finally start. It would then start on the first turn for the rest of the day.

Now it's gotten worse.... same symptoms, but it happens every time I start the truck. I have to push the clutch in and out half a dozen times before it starts.

It doesn't have anything to do with the clutch (other than the switch) because I can push the clutch switch button in and out manually and it will eventually start as well.

When I say "start" I should clarify that I mean turn over. It doesn't even turn over without messing with the clutch switch 5 or 6 times. Once it turns over, it starts fine.

It doesn't make any difference if I use the clutch bypass button, which to me is strange since I would think that would completely bypass the switch.

Any thoughts?

Thanks,
Matt

 

[Stick Figure]

Clutch switch is probably fine, but to test for sure, put a multi meter on the starter trigger wire at the starter, on the no start times if you have good voltage to it, its probably the starter solenoid internal contacts. If you have low voltage you may have a wiring problem, and if you have no voltage you could have a bad clutch switch, or wiring problems.

for the starter solenoid contacts, which can usually purchased from toyota (for a camry if they work in the 4Runner starter) or from a local starter alternator rebuild place. usually around $20-$30, and super easy to install.

for low voltage i have found the wiring to the starter solenoid itself starts to corrode and not be able to pass enough current to control engage the starter solenoid. The proper fix for this would be a new starter relay and some rewire. I have used a regular 30amp automotive relay and basically just added it in addition to the factory wiring. If you are going to do this you would run:

Terminal 85 of the new relay to the factory trigger wire now running to the starter solenoid, 86 would go to ground, 87 will go to the starter solenoid trigger, and 30 will go to the battery w/ a quality fuse holder inline.

 

[toytech76]

99% sure that is your starter contacts going out. Replace them and you will be fine. Dont go out and buy a junk aftermarket starter to replace yours

 

[Matt_Ledbetter]

Thanks guys...

so, toyota sells the contacts?

Thanks,
Matt

 

[Stick Figure]

Toyota sells them for a camry, which just happens to fit a lot of other toyota cars, not sure if they sell the 4runner specific ones, or if the camry ones work in the 4runner starter, i'm too new to the 4runners to know that just yet. Pull the starter out, and on the back side of the starter will be a 3 screw cover, remove that and you will be able to pull out the plunger, and then when you undue the wiring off the sides, the other contacts will be able to be removed.

 

[toytech76]

If they are any more than $25 let me know. I have tons of them I can sell

 

[Matt_Ledbetter]

3 bucks each at Texas Alternator in Austin... going to try to get them installed tomorrow morning, but I might put it off until the weekend.

Thanks for the advice everyone...

-matt

 

[Matt_Ledbetter]

Thanks for the help guys... replaced the contacts and all is well.

Thanks,
Matt