06 Tacoma Starter Spins But Doesnt catch HUGE UPDATE!!!!! I have another update....

@gody make sure you see everything that was replaced.
Trust, but verify.

 

It appears we have a much deeper problem. All the cables from the starter to the battery etc.. have been changed out. And the starter works correctly but only intermittently. Every XXX amount of starts the bendix does not extend all the way, causing it to just catch the tips of the grooves on the flywheel. The first mechanic even added a second ground which did not solve this issue. Its been sent to a mechanic that specializes in electrical issues. He said he cant figure it out either. He now has a intermittent problem that needs to be corrected or sometime in the future he will be replacing the flywheel again. Truck is basically undrivable. Might be the ignition switch or something in the steering column?

 

Can you monitor the voltage to the solenoid when starting? I'm guessing there's an intermittent low voltage to it and therefore can't push it out all the way. Run a wire so you can hook a meter up inside to check it out.

 

The starter can't spin until the solenoid extends and closes the contacts to the starter motor. The bendix is supposed to move with it and engage the teeth on the flywheel. So maybe the bendix is not working correctly or... is it possible the new flywheel has something wrong with it? I dunno, just taking a shot in the dark.

 

When the truck doesn't start, do you hear a grinding noise from the bendix and flywheel?

 

1. We know that the starter is not getting enough power, intermittently. We just do not know why. 2 mechanics and neither could not correct it.
2. We have had 4 different starters installed and all 4 starters did the exact same thing. Not likely a stater problem and we initially suspected the Bendix on the original starter was bad so we replaced it. Then we discovered the second starter did the same thing. Then we discovered the flywheel was bad. We did a complete clutch replacement so the flywheel is new. It was only 18 months old before it failed. Before the teeth were chipped awa7y to the point the flywheel was useless.It failed because the starter had been chewing it up for the last 18 months. The new flywheel has zero miles on it since we only started it to drive it to the next mechanic.
3. Yes we do hear a sound. Its not grinding since the problem is temporary. It works correctly for several start ups, then every once in a while, it will not. When it doesnt we hear a sound, before the Bendix finally engages correctly.

There is a problem getting the right amount of power to the starter consistently. Ignition cylinder? Some screw up in the column?

 

This is for testing purposes only.

Run a properly sized wire from the battery to a single pole single throw switch. Then run the output of that switch to the solenoid coil. Then you can place the ignition to on and then turn the starter on with the switch.

If it doesn't grind and engages properly every time that would prove it is a wiring issue with the solenoid circuit.

If you still have an issue then it would be somewhere other than the solenoid circuit.

 

Any big ground cables loose? Like between the engine and the frame? Or frame to battery?

 

This is very interesting thread, can't wait to see how it ends.

 

I like this plan. I also agree with op that it could be the key switch itself (intermittent high resistance in the start position), or possibly a bad relay, starter relay or solenoid relay, not sure what we have. A relay buddy tester would help here. Testing for voltage at the starter isn't testing the key switch, you would still see voltage there if there is high resistance in the key switch. I don't think it would cause this problem, but I'd also check for coolant electrolysis.

These are the kind of problems I like to challenge myself with, I wish I could get my hands in there. I hope it gets figured out.

 

I wish you were here! This is costing my son a small fortune and the guy that specializes in auto electric is stumped. We are worried that this cannot be resolved rendering the truck useless. I havent spoken to this second mechanic myself yet. I will mention the test circuit to him and see what he thinks. This type of thing is way beyond my level and I feel really bad for my son and that I cant help him. He worked a long time to buy this truck. Thanks everybody.

 

It could be a lot of things from the key switch to the connection on the switch to the wiring or the starter relay. It just seems too odd that the bendix gear doesn't extend all the way out, but the starter motor is turning. If there is enough power to run the motor and pull the solenoid it shouldn't be doing this. That is why I proposed the test circuit above to work around these components to see if the issue resolves and it will narrow down the search for the real cause.

** I'll say it again this would be for troubleshooting purposes and not a work around for the problem. I figured I should say that before people pile on and tell me how screwed up I am.

 

This has me stumped too.
If the starter works like I think it does, the bendix gear would have to be fully OUT to make contact with with the starter motor contact disk. Unless the contact connection is on a spring that also moves IN towards the flywheel? But it doesn’t look like it moves in the video you posted above.
Anyway, just out of curiosity.
I’d maybe look at the EB1 connection.
There were some truck that had a problem with moisture in a connection near this one.
(I believe it was for the Auto Trans trucks)
But at this point, almost anything related to the starting system is worth looking at?
Even though I honestly don’t think the problem lies there.

 

Yes I'm pretty sure it works just as you think it does. The solenoid is energized and it pulls the armature into the magnet which has a plunger post with a spring on it that presses the Bendix gear out to mesh with the flywheel. It seems to me that if something is stopping the gear from engaging then the starter motor contacts would not touch and the motor would not turn.

Watch the video and you can clearly see where he presses the plunger down and the gear extends. It is pretty direct connection between the plunger rod and the Bendix Gear.

I had to rebuild my solenoid a year ago and it doesn't take much wear on the contacts before it doesn't engage reliably.

I just don't see it.

This is the plunger in the solenoid. Maybe they have the wrong starter as the plungers are different lengths.

 

Our trucks do have a starter relay in the box by the battery, they are easy to test with a multimeter and 9 volt battery. Also have a neutral safety switch that can go bad. Autos are on the shifter and manuals are under the clutch. I guess you probably already checked these? Im having starter issues too! I need new contacts but my label is worn til I cant decipher if I have a 1.4kw or 1.8kw starter!

 

Go here: https://www.nationsstarteralternato...-with-Plunger-2-contact-p/drk rebuild kit.htm

$31.95 to rebuild the solenoid. New plunger and contacts.

 

Yeah I know where to get them, my dilemma is I don’t know which starter to buy for? The 1.4kw or 1.8kw? Im so lucky that the label on my starter has worn off and Thats the only way to know for sure without taking it out which I cant do cause it’s my only vehicle. I was hoping someone could tell by whats left of the label by some miracle.

 

Pretty sure they both use the same contacts and plunger in the solenoid.

Or go to the dealer and they should be able to look it up by the VIN.

Nations Starter will send you the correct set based on year, model and engine.

 

Well I was hoping that but seen others saying that the plunger isnt the same length and contacts are different. Wouldn’t be an issue but I can’t get stuck with my truck out of service and I sure don’t wanna squeeze that thing off and on twice because of wrong parts. By the way $31 is way high you can find the kits for $9 on ebay, maybe the $31 is higher quality but you can get a cheap rebuild starter for $45 whole thing.

 

If you can't afford to have your truck stuck out of service I would think you would buy quality parts instead of cheap Chinese knock off junk on ebay. If the contacts on the starter are worn sooner or later it will leave you stranded with an automatic transmission.

I was only trying to give you a tip. Take it or leave it...

When you pay for a 45 dollar rebuilt starter, that is exactly what you will get CHEAP.

Good luck.