Question about starter - 2006 4.0 V6 4wd

My starter has stopped working and is just clicking when engaged. I want to replace the plunger and contacts in the solenoid which I believe will fix it. The issue is getting the starter off, I'm almost certain I won't be able to do it without stripping a bolt given the amount of rust that is unfortunately on the truck. I've also heard conflicting information about whether or not the front driveshaft needs to be dropped in order to get the starter out. Does anyone know if it's possible to pull the solenoid cover and replace the contacts and plunger without taking the starter out? Any insight is appreciated. Thanks!

-Chris

 

I looked at trying it when mine shit a while back - it pretty much has to come out. I didn't need to drop the front DS to get it out, but it was tricky.

 

Before you do anything else check you electrical connections including your battery connection, and grounds.Many times what you describe is due to rusted corroded connections. Check your battery itself also. You may have already done this I don’t know.

 

Thanks, I've checked the connections and grounds and even installed a brand new battery. No luck. Time to attempt to get the starter out I guess

 

I removed my starter without removing steering shaft or drive shaft or exhaust manifold.
You have to remove the starter bolts and spin it flip it twist around until it can snake its way out.
Take off the rubber covers inside the fender well

 

I was able to fish my starter out through the driver side wheel well. I didn't have my intermediate steering shaft in place at the time due to another project, so unsure if that would interfere. If that does need to come out, it's just a few bolts.

That said, even after I replaced my starter with a reman OEM from Toyota, I still had starter woes on my 2005. It would just click once when turning the key. The solution was to replace the 4 gauge wire that runs from the battery to the starter because apparently it had internally degraded over time and couldn't deliver that juice needed. Visually, all connections were solid and clean, not corroded at all. I found the fix on a 20 year old Pirate4x4 thread of all places. The way I tested this was by running a jumper cable from the positive terminal on the battery to the stud on the side of the starter, and then turning the key. The truck fired right up.

A 3ft one with 3/8" lugs is what I used, and it solved my problem. Just something to keep in mind.

$17 4 AWG Gauge Fully Assembled Battery Cables, 1-15ft Lengths, Positive or Negative Wire, Pure Copper Battery Replacement Cables, Solar Car Truck RV Camper (2ft, Single Red, 3/8” Lugs)

https://www.amazon.com/gp/product/B09QMWDJHG?ie=UTF8&th=1

 

Thanks for this info! I was able to remove the bolts holding the starter to the engine. The nut holding the 4 gauge wire to the starter is seized and I'm likely going to cut the cable, remove the starter and replace it when reinstalling. Thanks for the link, I'm going to order that 4 gauge cable. Just to confirm, based on the wiring diagrams I've seen, that cable goes straight from the positive battery terminal to the starter, correct? I'm going off of wiring diagrams since the cable is obscured by other wiring looms in the engine bay. Want to make sure I get it right. Thanks!

 

Yep! If I still had my truck I would send a pic, but IIRC it’s the 4 gauge cable on the positive battery lead that has the weird 90° end crimped on it.

edit: I was unable to fully fish out the old cable because I couldn’t get it out of the plastic loom it ran through. I just cut the cable on each side so it wasn’t visible anymore.

 

Here are some details about that little bullshit wire bracket and the routing of the starter cable in general:

https://www.tacomaworld.com/threads...ow-descent-into-madness.712981/#post-25374805

Closeups of the plastic dude:
https://www.tacomaworld.com/threads/alternator-starter-wiring-housing-solved.713297/

 

Maybe you can break the stud off the starter if the starter is bad.
I think the solenoid has a plastic end where the stud is

 

Thanks everyone. I cut the starter cable and was able to get the starter out through the top of the engine bay after some careful maneuvering. I ordered a replacement starter cable (thanks for the link!) and the solenoid rebuild kit from Nations Starter and Alternator. Will update once the kit comes and I have the starter back in the truck! The rear of the starter has a small crack, which I think I'm just going to superglue to prevent water intrusion.

 

There’s a video & I did some instructions once you get it out.

https://www.tacomaworld.com/threads/new-starter-source.718589/

 

Well dang. I replaced the plunger and contacts, new cable from the battery to starter. Got everything back in and it still is just clicking. It must be the starter itself, not the solenoid in this case? Going to the dealer now to see what an OEM replacement will cost

 

I believe rockauto carries denso for significantly less than the dealer will. Same part, no Toyota logo on the box.

 

Try charging the battery up. Or jump charging, use another vehicle, connect jumper cables, bring rpms up, see if it starts. If yes, drive it or leave it running. See if that helps. Also check the connection battery to battery terminals.

 

Wow. I’d thoroughly inspect the starting system in full before I pulled the starter again.
Sorry I didn’t see this post sooner.

Thank @Dm93 for the awesome “DIY Diagnostic”.
https://www.tacomaworld.com/threads/2nd-gen-information-diagnostics.784008/#post-28042155

 

Sorry for the late update! I got a Denso starter off Rock Auto and it works great! I guess it was the starter motor itself after all. Thankful for everyone who helped out!