morroweh

Hey guys. Been trying to figure out why my 89 2wd 3.0 manual wont crank sometimes. Roll starts real easy and when it does crank, it does quickly with no problem. Battery is good. When no crank, I hear at least one relay click, maybe two but thats it. i feel like the solenoid is not going but its getting the signal (i think). Looking for things to check for. Any advise is appreciated. Thanks. Also, if anyone knows where i can find a wiring diagram for this truck that would be great!

2ToyGuy

Check this thread: https://www.yotatech.com/forums/f116...runner-307493/

It might help. This is a common problem, as the starter circuit is very poorly designed.

Good luck!
Pat☺

RAD4Runner

Most likely this^^^ but we need to see, hear, feel what O.P. does...

Let me assure yours is a simple problem to solve, and many other owners have had it.
Before we can help you from miles away and over the web, pls:
1)Read post linked above. I describe in detail what to see, hear, feel.
2)Describe in detail and with certainty exactly what you're seeing/hearing/feeling. If you only "think" what the solenoid is doing, or guess where/what relays are that would not help.
3) Show us those parts you're talking about. Find your starter relay. What color wires go to it.
4) Pick up a multi-meter.
We'll go from there.

morroweh

I did your starter solenoid terminal to battery, RAD. The first couple of touches to b+, nothing but small sparks. Every touch after gave a good clunk of the solenoid. Nothing from the motor. Same results through the key. The starter is aftermarket and a few years old. Is this a motor brush problem? Relay is in driver kick panel. Is there much difference between the 2.4 and 3.0 starter as far as diagnostics goes? Thanks for your help.

RAD4Runner

There you go!
Make sure you have bare metal to bare metal from batt to starter stud termimal, batt neg to engine block ground.
Then suspect starter solenoid contsct,
Then starter motor itself.
Once done with above...
Does your start relay lool like JPL's in my post? (green I think). If so, need to add a starter relay
PHYSICALLY between batt and starter.

morroweh

Thanks! battery to starter connections all good. still need to verify block grounding. Looks like I have a reman starter. Any way to figure and get the right replacement contacts without taking the starter off and out? ...That is my starter relay i do believe. Cant seem to find your jpl post again, but from what i remember it looked like this. Does the poor wiring design shorten the life of contacts? Thanks.

RAD4Runner

IF solenoid clunks energetically and battery connections to starter are good, only suspects left are the starter motor/winding or the solenoid contact. Not aware of a way to check without removing starter.

Yes, poor wiring means solenoid contact may not tightly close; causing heating or possibly more arcing. See how an outlet/plug heats up when you use your flatiron? That means poor/loose/oxidized connections = resistance = power lost at connection inform of heat.
If yours looks like JPL's, wiring is likely electrically-correct. However, load current has to flow an unnecessarily long way...

morroweh

Thanks RAD! Very helpful. Ordered some new contacts. Got them in no trouble. Old ones were pretty warn and the plunger ring pitted. Started right up. Added the extra relay. Very confident in this fix. Now to find out where all this oil is from. Thanks again. Learning so much from y'all.