Starter Motor Clicking Troubleshooting and Repair Guide

Toyota Prado 90 Series
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Introduction

This guide provides information on diagnosing and repairing a common issue where the starter motor only clicks without engaging the engine. This often results from worn contacts within the starter solenoid.

Problem

The starter motor makes a clicking sound when the ignition is turned, but the engine does not crank. This indicates the solenoid is engaging, but power isn’t being properly transferred to the starter motor itself.

Solution

The most common fix is to clean or replace the contacts within the starter solenoid.

  1. Remove the Starter Motor:

    • Manual Transmission: The starter can be removed from the top of the engine bay after some twisting and maneuvering. It fits between the exhaust and upper suspension mount. No need to disconnect steering components.
    • Automatic Transmission: Remove the top half of the automatic transmission dipstick tube and move the brake lines. Access is easier by removing the driver’s side wheel, then removing the starter through the wheel well.
    • Note: Some users have disconnected the power steering lines from the rack (using a 17mm flared nut spanner) to gain access, but this is not always necessary.

  2. Disassemble the Starter Motor: Carefully disassemble the starter to access the solenoid and its internal contacts.

  3. Inspect and Clean/Replace Contacts:

    • Inspect the contacts and plunger for wear.
    • Clean the contacts thoroughly to remove any corrosion or debris. Light sanding may be necessary.
    • Alternatively, replace the contacts and plunger if they are severely worn.
    • FIX: Replace worn contacts in the solenoid.

  4. Reassemble the Starter Motor: Reassemble the starter motor carefully, ensuring all components are properly aligned.

  5. Reinstall the Starter Motor: Reinstall the starter motor in the reverse order of removal. A ratchet spanner can be helpful for tightening the top bolt from the engine bay.

Relevant Parts and Tools

  • 17mm flared nut spanner: (If disconnecting power steering lines)
  • New Starter Relay: (Potentially, although contact cleaning is more likely to fix the issue)
  • Socket set with long extension and uni-joint: For reaching the top starter bolt.

This technical summary was auto-generated based on recovered archives. Do not rely on its factual accuracy. Refer to the original thread. Source: View Original Conversation

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