'99 Toyota Tacoma- contact replacement in starter solenoid

chiefjason

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OK, I've been having some issues with the truck starting. But I've also had some issue with battery connections and thought it was all one issue. Nope. Today I cranked the truck and it made an odd humming noise. Went to turn it off and it acted like it was still trying to crank. Turn key on, not cranking just to the on position, it would crank. Finally had to disconnect the battery to get it to shut off.

Did some digging on the net and found it's likely the starter solenoid hung up. Contacts either bent to welding from a large arc cause by poor fit. Banged on the solenoid and got it stopped. Temp fix at best. So looking into it the cheapest thing is to replace the contacts. Kind of a mini rebuild.

Soooooo, there seems to be some changes over the years with contact parts. So several possibilities out there that might or might not work. I'll assume here that any box auto parts store may not be terribly helpful. So taking a stab in the dark whether anyone has part #s for starter solenoid contacts on a 1999, 4 cylinder, 4wd Toyota Tacoma. Going to do some digging around tonight myself. The site with the replacement instructions seems to have a link to buy them, but I have no idea about the site. It's 4crawler.com and they have a kit with all the available sizes at a decent price. But the site looks a bit cheap and cheesy.
 
chiefjason;n52780 said:
OK, I've been having some issues with the truck starting. But I've also had some issue with battery connections and thought it was all one issue. Nope. Today I cranked the truck and it made an odd humming noise. Went to turn it off and it acted like it was still trying to crank. Turn key on, not cranking just to the on position, it would crank. Finally had to disconnect the battery to get it to shut off.

Did some digging on the net and found it's likely the starter solenoid hung up. Contacts either bent to welding from a large arc cause by poor fit. Banged on the solenoid and got it stopped. Temp fix at best. So looking into it the cheapest thing is to replace the contacts. Kind of a mini rebuild.

Soooooo, there seems to be some changes over the years with contact parts. So several possibilities out there that might or might not work. I'll assume here that any box auto parts store may not be terribly helpful. So taking a stab in the dark whether anyone has part #s for starter solenoid contacts on a 1999, 4 cylinder, 4wd Toyota Tacoma. Going to do some digging around tonight myself. The site with the replacement instructions seems to have a link to buy them, but I have no idea about the site. It's 4crawler.com and they have a kit with all the available sizes at a decent price. But the site looks a bit cheap and cheesy.

Tacoma world.com
 
We had to replace the contacts on my son's '94 Toyota pickup. I can't remember where we got the parts but it only took a few minutes to replace. I text him to see if he remembers where we go the parts.
 
chiefjason;n52902 said:
You da man! Any reason to replace the plunger or just clean it up? Found a kit that includes contacts and plunger for $31.95 and shipping. With that little price difference it might be cheap insurance.

http://www.nationsautoelectric.com/densoparts.html

A coin toss. I have done just the contacts quite a few times with success.
 
Just ordered the kit from Nation's Starter and Alternator. The new site for the above link. Called, talked to a guy and got me to the new site and walked through it. Should ship today. Less than $40 for plunger and contacts, not going to complain about that. They even have a spiffy youtube vid for rebuilding it. Now to get my hands dirty when it gets here.
 
Well, they took their time shipping the parts, then busy weekend, had DOT physical on day off; finally got to it today. Took longer than they say, which I always expect. About 2 to 2.5 hours including getting everything together. Removing it was tougher than putting it back. Rebuilding it took about 10 minutes. Pics to follow.

Had to access the starter through the drivers side wheel well, 4wd is like that apparently.




After fighting with electrical contacts, connections, and some new yoga positions to get to the bolts; success.




This is the cover to remove to get to the contacts.





Cover off, that's the plunger pushing out.





Corroded contact side of plunger, glad I ordered the kit. Otherwise I would have been doing some sanding on this thing.






Worn contacts.




Bolts to remove contacts are on the outside.




Worn contact on the left, you can see the gap that has worn as it compared to the new one on the right.



It cranks like a champ.
 
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