Starter won't stop!?!?

[gezebo]

My brothers 99 corolla just got a new engine(swap) few months ago. the car ran fine. recently he's had problems with the starter working. It sometimes just clicks, and sometimes started. tell signs of a dying starter. so we replaced it with a reman starter from O'reily's.

Fresh starter works great at first. Then seems to develop issues. He's having 2 main issues now.
1. The new starter now is clicking again sometimes, and starting normally sometimes.

2. The new starter seems to be seizing up. It sounds like it starts and then the spline doesn't disengage from the flywheel and the Flywheel keeps the starter spinning. This is weird and I know there are alot of variables to keep in mind, considering he just had a newer engine put it.

Needless to say, the shop did a shotty job. He's already had to replacy some brackets(used to hold small wire looms infront of engine).

We're suspecting a grounding issue, however have checked all visible ground connections, and they seem to be fine. My bro says he will test for continuity later after work.

Any other thoughts on what this could be? Help is appreciated.

[edit: My brother tells me this was happening to the old starter as well, thus he decided to just replace the whole thing]

[wiccanferret]

You got a bad reman starter...it's not ALL that uncommon. Get it replaced under warranty.

[toyomoho]

Usually the contacts of the starter solenoid are defective, they either don’t make proper contact (clicking) or don’t disengage properly (starter remains on with engine running). Did you replace both the motor and solenoid?

The starter motor may have an alignment problem when installed resulting in binding with the flywheel ring gear and starter pinion, check the teeth on both.

Check the wiring and starter relay circuit. A bad ground may cause clicking but the starter solenoid can only disengage when DC power is removed (unless the contacts are welded together).

it is possible to operate and test the starter/solenoid system when it is removed from the engine.

[gezebo]

Originally Posted by wiccanferret

You got a bad reman starter...it's not ALL that uncommon. Get it replaced under warranty.

Thanks for the heads up on this. see [edit: above]

I did dig a little deeper and found another thread in the tacoma section about similar issue, however suggest replacing contacts in the solenoid. I'm not sure this is a solution for us since we replaced the whole starter. But Might have to check the connectors on the starter.

[gezebo]

thanks toyomoho,

The entire starter was replaced(with solenoid). And as I added in my edit, since this was happening with the old starter as well.. I'm leaning towards your other suggestions about the wiring.

My guess is that the shop that replaced the engine left some loose connections. will have to check the starter relay too Thanks again for your help.

[dictatormao]

Hey guys this is my car we are talking about...to shed some light on the subject I purchased a new starter relay from toyota (72 bucks!) and it DIDN'T solve the problem. I am going to trade my new starter for another one...see if that makes any difference...if it's not that then I figure I'll try the ignition switch.

If you guys have any suggestions or ideas please let me know. My battery is a Sears Die Hard Gold purchased 2 yrs ago.

Mao

[dictatormao]

got the car started today but no more clicking...do notice that when I have the ignition engaged all the lights will dim. I have checked the battery with multi-meter and it measures 13.5 volts across the terminals. suspecting bad battery cables. did voltage drop test on negative 0.03 volts drop. negative cable very corroded. going to replace that first...if you have any suggestions please let me know.

[DMC6453]

It is normal for the headlights on a car to dim slightly when the ignition is engaged due to the large current draw of the starter. If the dim is more than normal, there is a problem.

My 98 corolla also had a starter problem where it was clicking and I called an auto electric shop and they told me that most likely the solenoid contacts were bad. I bought new contacts for $10, removed my starter and installed the new contacts (the old ones were very worn), reinstalled the starter and now it works great . I can post a picture of the worn contacts if you like.

-Chris