Intermittent click with no start

Hoping someone can help diagnose my issue.

My 2nd gen had the problem where when I turned the key, there would be a single click from the starter solenoid but no crank. I pulled the starter and put new contacts in the starter solenoid, and that seemed to fix the problem. Fast forward a few months, and it's happening again. The truck has a new battery, and fresh contacts in the solenoid. What else should I be looking for? Battery ground? Armature or brushes? Relay?

95% of the time the truck will start with no issues, it's only occasionally that it doesn't crank.

 

Check and clean all battery cables, including ground cables on frame and engine, and positive connection at starter

If you have a multi-meter look up some videos on how to voltage drop tests along all the power and ground cables during a cranking attempt

Might still need a new starter though..

 

After you’ve looked up how to do the starter voltage drop test. I’d first test at the battery positive and negative posts. Ideally testing on the posts instead of clamping onto the terminals but not necessary if you don’t have an extra pair of hands. Also ideally to have a meter with peak hold. Next test at the battery negative and the big positive post on the starter. Comparing your two results will tell you how much you’re losing through the positive cable.

When you put in the new battery, if you didn’t use a battery brush on the terminals, that could cause a problem. A battery brush is cheap, and it’s simple to rule out a possible problem. Just because it “looks” good doesn’t mean it is. When you remove the terminals from the posts, that’s when you could find oxidation on the terminals and or posts.

 

Thanks for the advice, going to check it out with the multimeter this afternoon and clean all the connections I can find.

I was having trouble tracking it down because most of the time it starts strong, it's only every 20th or so attempt I get no power at all

 

Classic corrosion issue.

 

Voltage drop looks good. When you say corrosion issue, what's being affected? Is it worth swapping the brushes, or just replace the whole starter?

 

When it clicks do you have good power at both the S terminal and the stud where the big wire attaches?

If you do it would seem it's a starter issue.

 

Yes, I'm getting less than 0.2V drop, so the wring seems to be in good shape(or my multimeter is out of calibration). When the truck starts, it starts great, and I haven't had another failure to start yet for me to test it in that condition.

 

Any ideas if replacing the brushes is worth doing? I've already replaced the contacts, so pulling the starter isn't an issue if it has a possibility of helping

 

Could be the contacts failing again as well, I don't ever discount new parts as being good especially in today's parts economy.

 

I think I'd just put a starter on it at this point if you can verify it's the starter.

 

When a starter is commanded to spin it has to do 2 things. The drive gear has to spin and it also has to move forward and engage the ring gear.
The clunk is the drive gear moving forward and hitting the ring gear, thats the solenoid contacts that you replaced.
If it was spinning you'd hear it. That's the job of the brushes. You should have done them too while you were in there

.2 voltage drop is just fine

I'd just put a denso reman in it

 

0.2v drop. Assuming you’re talking about starter voltage drop tests performed at the battery terminals and at the negative battery terminal and big lug on the starter, 0.2v being the difference between the two tests.

If your meter is off, it’s going to read off on both tests so it doesn’t matter.

If you already brushed the battery terminals and posts with a battery brush and don’t have any loose connections on the starter and you know for certain the neutral start switch or clutch pedal switch is good and the starter relay is good I would go ahead with a denso reman starter.

https://www.tacomaworld.com/threads/2nd-gen-information-diagnostics.784008/

Scroll down to post 4.

 

Reman starter is what I'm going to go with. Anyone happen to know a good source for one in Canada?

 

Rockauto still the best price, even with cross-border shipping. Thanks everyone for the help, hope this is the last fix!

 

Did you replace the plunger? There are really three contacts. The two you replaced and the round one on the bottom of the plunger. All three need to be in good shape. If the round one was all pitted, it could have quickly trashed the two you put in. The plunger contact often looks pretty good so some guys don’t replace it. However it can get beat up sometimes and then must be replaced.

 

Always replace the plunger / contact along with the other two.

Nations starter has a kit with everything.

https://www.nationsstarteralternator.com/Starter-Rebuild-Kits-s/37.htm