I just put new contacts in the starter of my 88 V6. I put it back in and it worked fine, but I found the little spring that fits over the end of the plunger shaft sitting on my workbench. (I hate it when that happens!) I took the starter off, replaced the spring, and bolted it back up.

When I tried to start it, the starter turned, but didn't engage the flywheel. Instead, I could here it grinding against the flywheel. When I took the starter off, I could see where the dirt was worn off the front of the starter gear, as if it was pushing against the side of the flywheel, rather than engaging it.

The starter looks fine, and th plunger works easily by hand. The little ball that the plunger presses on is still there and, as far as I know, I didn't forget any more parts. I was hoping to find the casue before I put it back in, but I can't find anything wrong.

Any ideas?

Mark

I have the following information on my starter repair page:

"One item take note of is that that there is a ball bearing that drops into a hole in the end
of the clutch assembly. The spring that rides on the plunger in the solenoid rides on that ball bearing. Whenever you take the starter solenoid apart to replace the contacts, make sure that the ball bearing remains in the hole in the end of the clutch assembly. It can come out and yet remain inside the starter and cause a grinding noise and lock the starter if it falls into the right spot."

Roger, I recommend your page all the time, but yet didn't read that paragraph myself. I bet that's the ticket.

Thanks!

Mark

Roger, just a public thank-you for all the info you post on topics such as this one. And the FSM covers it NOT AT ALL!

I recently fixed the starter on my beater 2WD and used the trail spare contacts from my 4Runner, previously purchased following your advice. I now have new contacts and a fully functional starter in the 2WD and still have a perfectly serviceable trail spare contact (starter motor side, used) for the 4Runner, for $12 and a couple hours leisurely work.

Man- not much space to work with in the 2WD!!!

same problem on my wife's car. After replacing
the brass contact, the click-click is still
there. It is sometimes not all the time click-
click. It's an '87 toy supra. The starter is pita
to work on. Tried removing once before and took
me about 5 hours to remove and install. Does this
model has the lsd? how do i know? thanx

Well, I found the problem so I thought I'd post it: A weak battery. I knew it was not fully charged, but I'd been doing all my testing a battery cahrger hooked up in "engine start" mode. Turns out that wasn't enough. I left the battery on the charger for awhile and it started right up.

I'm not sure why it worked fine a few times, then stopped working afer I replaced the spring I forgot, unless that added just enough extra tension to bounce the not fully energized plunger back out.

Mark