Hot starter won't start

[MrSkott]

Hello all,

I have a 1991 Toyota DLX Ext Cab 5 speed with the 3.0 V6.

My problem is this: When I run the truck and it reaches running tempurature, the starter will no longer start. Thinking that the solonoid contacts might be worn, I pulled the starter out to inspect. In an attempt to get the new contacts from Toyota, I just decided to get a Bosch re-built as the original already had 205,000 miles on it. Long story short....the newly installed rebuilt starter is exhibiting the exact same problem. If I do the ole BANG on the side of the starter trick it will reset enough to start sometimes....others I must push start. Either way its a pain....a big one. Another note....on cold it starts faithfully. Any ideas? I need a real solution here. This has been a year long saga. Thanks for the help in advance.

[texas12]

Let me guess! You turn the key, have full lights and power, but the starter will not crank the engine.
Join the club ! I have had this problem on my 86 4runner for the 2 years I have owned it. Replaced starter, battery cables, ran extra ground cables, replaced circuit opening relay and , yes banged my head many times.
If you install a volt meter on the start solenoid, you will notice only about 7-8 volts trying to kick the starter contacts. Not enough juice. Where is it going? I don't know. How do you rig it?
I ran a starter switch from battery '+' to inside the cab and back to the starter solenoid connector. On the occassions that it doesn't start, just turn the key ON and push the button. Works every time.

[MrSkott]

Yep, once hot and I try to start I hear a very high pitched whine noise...thats when I know I have to go bang on the unit. Very frustrating.

[Tercel GTS]

use a ford solenoid to setup a booster, need a wiring diagram?

[MrSkott]

Yah that would be cool...thanks bud.

[Tercel GTS]

[MrSkott]

Thanks...you wouldn't happen to have a part number for that ford solenoid? And I take it that the solenoid acts to bump the voltage back up to 12?

Scott

[Tercel GTS]

All fords used that solenoid from 1965 till about 1980, then they went to a flat one that is JUNK. It eliminates the voltage drop by shortcutting a direct power supply from the battery to the starter solenoid. If you ask for a solenoid for a 1977 truck you'll get the right part, regardless of engine size or anything else.
And make sure the ignition wire from truck goes to the terminal marked 's' on the ford solenoid

[CraigW]

I think they made 1 or 2 of those solenoids over the years.

Did anyone ever see a mechanic try to start the engine by using Channel Locks clamped across the contacts of one of those solenoids ??

[texas12]

Now wait a minute. If you are getting a high pitch whine, it sounds like the starter is spinning but not engaging the flywheel. That ford solenoid would not help in that case (but would in mine ).
Thanks for the solenoid tip GTS. I might try that.

[MrSkott]

The whine is barely perceptible and is very very high pitched. Someone once guess that the solenoid on the toyota starters have a overheat protection and that it might be that since the problem is only during hot conditions...but for the life of me I can't imagine what is different now then when it worked fine. The exhuast manifold is good, alll fluids are steady and changed regularly. My temp guage runs normal. Still a mystery I suppose. Tex, you still think its a voltage drop on the hot conditions and that a direct wire starter switch is the way to go?

Scott

[texas12]

The starter switch has worked for me for some time now. However, GTS's suggestion is also good.
The poor man way (I did it for several months while troubleshooting) is to run a wire from the starter solenoid to somewhere near the '+' battery post. Make sure it is tied off good and will not short. When it won't start, pop the hood and touch the wire to the '+' post and the starter will crank. If the key is in the 'ON' position, the truck will start. Make sure it's in park or it will run you over