I replaced the contacts on the starter almost 2 years ago and now all of a sudden today I got the "click" when I turned the ignition key. Several attempts later I got the same result.
Luckily, the 4runner was parked in my garage so I just pulled the starter and popped the cap off to inspect it. The terminals still look new but the circular contact on the plunger/stator thing is a little pitted.

At this point, is it time for a new starter or is their something else I can do to revive it?

Also, is there a safe way to bench test it?

 

auto zone/pep-boys/o'reilly's all will bench test it for you.....

 

Thanks. I might give autozone a try tomorrow.
I just wire brushed that circular copper piece and both contacts. I also tried cleaning the rest of the parts with some electrical parts cleaner. We shall see.... Or ...should I take a chance and just reinstall it? I'd hate to make more work for myself

 

Mine did that crap on my 1st gen and the starter solenoid contact had come loose, still on, but loose and wasn't getting good contact. Crimped on a new female connecter and it has been good ever since.

 

I just tried bench testing it and it seems the starter gear pops out but it doesn't spin.

edit: I gave the motor part a few taps with a hammer and now it spins. Crap. I don't know if I should replace it or not.

 

Try cleaning and lightly lubing the parts inside the solenoid and the gear. You can lightly sand the ring onthe plunger to clean it up. If you hit the solenoid (only) w/ power, it'll pop out the gear but that is it. You'll need to have the heavy cable connected to the battery to get the motor spinning (and w/o a load on it, it'll go really fast). ANd you should check the voltage at the solenoid (under load) to see what it reads. If you notice a large voltage drop when trying to start, then you may have a wiring issue upstream from the starter:

http://www.4crawler.com/4x4/CheapTri...l#OtherOptions

 

Roger thanks for the reply. I actually used your website to figure out how to test it.
I have remedied the problem but have unfortunately pissed away $160. I did something really stupid. No, REALLY stupid.

The reason I decided to buy a new starter was just for peace of mind. I popped in the new unit and turned the key only to hear the click again.

Now I had already ruled out battery terminal connections because I just cleaned them a few days ago. But at this point since the starter is ruled out, I have to take everything apart at the battery and wire brush it again to be sure.

Well folks, wouldn't ya know, I wire brushed everything connected it back up and wahlah.

Here's the good part and the reason why I am banging my head against the wall. When I cleaned up the connections a few days ago, I sprayed battery terminal protectant on the wire ends and then assembled the connections
I shot myself in the foot on this one.
This mistake probably ranks up there as #1 with me. The worst part about it is this new starter doesn't sound as ballsy as the Toyota one and I can't even return it.