2nd Gen Starter Problem - Starter? Relay? Gremlins?

I have replaced my starter for the third time since I purchased the truck new.

I have a 2009 4.0.

The first starter replacement was around 40,000. Replaced it with a rebuilt one. That was good until about 84,000 miles and I replaced it again. Then a few days later it wouldn't start again. Made sure there was good voltage (I have two batteries and they both were 12.6-12.7). I made sure that all connections were clean - including the terminals at the starter.

I then swapped the starter relay that looks like this:


Bam - started like a champ. ...up until today (about 3 weeks after changing the relay and the starter). So I took the original relay, plugged it in and, once again it started with no problem. The truck has been very reliable but this is a bit puzzled and feeling a bit insecure since I'm on my way to Mexico next week.

As I am going thru my trail spares I pulled out my original starter and looked at the plunger and contacts and thought there was no reason that shouldn't have worked. Bench tested it and it was fine.

I welcome anyone with any constructive ideas or entertaining posts to please chime in. I want to feel confident that I will start. I would love to hear someone that had a similar problem and found a permanent solution to the same problem.

Thanks in advance.

 

Are you installing autopart store rebuilt starters? That can be an issue all on its own.

How old is the battery? Just because it reads good in an idle state doesn't mean that it has the cranking power. Have it load tested by a reputable shop.

Read the battery voltage when starting and see how far it drops. That will tell you a lot.

 

I more than understand about the rebuilt biz - most are JUNK. The batteries are Oddesy Mfgd DieHard Platinum 1 year old.

Good point on measuring the voltage on starting - I will do that next time it happens.

My thoughts are if it was a bad starter, swapping the new relay with the old, or vice versa (I've done the swap a couple of times and each time the issue goes away - for a while) shouldn't make a bit of difference.

Thanks for your input.

 

Maybe check the starter's "solenoid" as well? Could be that's what was part of what's causing the problem? Yes, even though you switched out the original "Starter" with a "remanufacturerd" one but as previously stated, it's not an original-it was an autoparts rebuilt one.

This is my advice and yes it will be a bit of money but still you will have covered just about everything with starting your Tacoma?

Change/buy all parts brand new from Toyota:
1.) Starter
2.) Relay
3.) Battery

Also make sure that your battery cable connectors are clean'd real good as well as the cable and connector that connect to the Starter/Solenoid.

If problems still presist then looks like you'd have to take it in to Toyota to determine exactly what is the ROOT CAUSE of problem?

Good Luck and post back on your findings? I'm now curious on the out come.

 

Maybe the relays' connection in the fuse box is the cause? Or the wire connections under the fuse box to the box itself are loose or corroded?

 

A friend had similar problems on his Rodeo and it turned out to be the ignition switch.

 

Good points.

 

If it happens again, try wiggling the relay, and also the wiring harness that goes into the fuse box. If that doesn't do it , just unplug and plug back in the same relay without swapping. Similarly check the ignition switch and it's plug in the harness. At least they're free, easy and clean to try. Good luck.