My 95 Rodeo has devoloped the click, click, crank syndrom. After reading all the replies on the PITA <img src="/forums/images/graemlins/butwiggle.gif" alt="" /> job of pulling the starter for both Rodeo's and Trooper and checking out source of contacts one post mentioned possiblity of changing out contacts with starter in vehicle on a Toyota. After eyeballing what little I could see for the 4th time I couldn't even see the bolts on end of solenoid housing. But what if I just removed starter, rolled it around to expose solenoid cap? UREKA!
1. Disconect battery
2. Unbolt starter, short bolt on top, long on bottom. 14 mm deep socket with "wobble" extension ( like universal joint but less movement I don't know correct name) worked good for top bolt.
3. Slide starter out, roll around until you can get at wire attachments.
4. Remove cable nut (12 mm), large cable and small wire.
5. Roll starter around to put solenoid cover on bottom so you can work from under vechicle.
6. Remove 3 small cover bolts (9/32 socket worked) & remove cover
7. Plunger and spring will fall out. There is a ball bearing at end of plunger that can fall out. Mine stayed in place.
8. Remove wire from solenoid to starter (12mm box end or socket)
9. Remove nuts on contact bolt (14mm) I had to grind down my Craftsman 14mm socket to allow it to engage small exposed nut surface on starter side.
10. Remove contacts taking care not to break small wire going from starter side to inside of relay coil.
11. Replace with new contacts and reverse order to reasemble.
Note: Contact on starter side is smaller I ordered a "A" size for that and a "B" size for the other side.
Contact source:
http://www.4crawler.com/4x4/CheapTricks/Starter.shtml#OnlineOrderingContact bolts have "O" rings that must be removed from starter side before bolt will slide out and free contact.
Total time to remove about a hour including figuring out if might be possible. Didn't even skin my knuckles.
I just ordered my contacts so wish me luck on re-install. Total cost with shipping $12.72
Local garage wanted $360 plus tax to replace starter.
Thanks to all the posts that gave me the info needed to make this PITA project a routine money saving project.
John,
jskadberg@mac.comRamona , CA