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I replaced the contacts in my starter this time last year and it's already clicking again at times. Can anyone explain how contacts could be gone again in just a year?


Easy... How old is your battery? What CCA rating is it? How old are your battery cables?

If your starter does not get an adequate power supply, it will burn the contacts out faster. The low power starts are heating up the contacts to the meltdown point every time, and soon, you lose the starting ability again.

Change the contacts, then upgrade the battery cables to 2 or 4 ga. Drop in a better battery. All starting problems should be gone for a looooooong time.

I run an 875 cca (at 0*f) battery, 2 ga battery cables, and marine terminals. I have no corrosion problems whatsoever, and the starter spins faster than the day the 4Runner rolled off the assembly line in June of 1987. I also run a segment of the original negative cable (8 ga) from the negative terminal to the body. Best ground strap I have found (compared to the 14 or 16 ga wire from the factory).

I plan on these contacts to last for at least 200,000 miles (originals lasted 160,000, due to good battery maintenance). It took a bad battery cable to finally do in the original contacts.

"A young man who does not have what it takes to perform military service is not likely to have what it takes to make a living." - John F. Kennedy

Proud owner of an 88 Montero (with a blown engine).