I am super stumped with a no start issue. Please help

Hey guys, I'm have the craziest problem with my 1999 Tacoma 2.7L

A few months ago, the starter would not disengage. I had really bad contacts in the starter solenoid so I had those replaced and I was back in business.

Now, slowly over the course of two weeks, when I turn the key to start, I hear nothing but the sound of a clicking relay and the fuel pump priming.

Things I have done and tested:

Battery is good, even threw a new battery in it just to double check.

I cleaned the battery cables.

I removed the starter, jumped the solenoid and it works.

I went to auto zone, bought a starter which I have since returned, installed it and same problem.

I tested the voltage at the starter, same as the voltage as the battery.

I tested the signal wire at the starter with the help of a buddy, and it gets the same voltage as the battery when the key is turned to the "start" position.

Then I thought it must be a bad ground so I ran a heavy duty jumper cable straight from the negative battery terminal and clamped the other end to the body of the starter. Still nothing.

I bench tested the starter relay even though I know I'm getting power to the signal wire. It is good.

I thought it might be the neutral safety switch so I put the truck in Drive, turned the key to start and received no click from starter relay. Seem like its doing its job.

The only thing I have not tested in the ignition switch but since I'm getting power to the signal wire at the starter, I feel that it is ok.

I have read every thread on this type of issue and feel like I have troubleshooted everything. What am I missing here?

Thanks for any help in advance. Sorry for the long post.

 

Voltage drop tests.

Even if you have 12.x volts at starter, you could still have a bad cable. Do a voltage drop test on everything, that means you have to do it while trying to crank.

That's the only thing I can think of because it seems like you have all the other bases covered.

 

I appreciate the help. I will test that out and report back. I forgot to mention, I bought a 4 gauge generic battery cable and bypassed the positive lead. Its connected to the positive terminal straight to the starter just to rule out a bad positive battery cable.

 

http://www.bakesonline.com/images/MediaLibrary/IndmarStarterVoltDropTest.pdf

 

Read it, know it, love it.

I hope this helps solve your problem.

http://www.autotechnician.org/starter-voltage-drop-test-explained-in-plain-english/

 

Neutral safety switch ?
Edit , my bad ....he tried it

 

But he's getting 12v to the solenoid from the ignition when he turns the key?

 

^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^

This, I just went thru it, get another starter cable, get one a little bigger in gauge if you can, your getting juice, even 12v+ but your not getting the amperage, go thick copper...

 

First off, I appreciate the time and help you guys have given me. So far, no dice. I have preformed some more tests and here are the results.

If I jump the solenoid by using a jumper wire from the battery lead that connects to the starter, to the connection where the signal wire hooks up, the truck will start. I do not have a a voltage drop issue.

Since I am getting power from the signal wire, I thought maybe the connector was bad or worn out. So I used my jumper wire again, cut off the connecter and stripped the wire and made sure I had a good connection. The starter would not turn.

What has me stumped is the fact that I have 12 volts from the signal wire when I turn the key to "start" but it is not triggering the solenoid.

Is there something that could cause the signal wire to have the correct voltage but not enough amps to trigger the solenoid?

 

I'm going to guess (and I am probably completely wrong) but I'm gonna guess Ignition Module.

 

I was thinking the same. Clicking solenoid basically means everything is working. It's either a pooped starter or the high current positive cable can't flow enough current. Is it the starter solenoid clicking that you're hearing?

 

Idk if you guys read my last post but if I had a bad ignition module, would I get 12 volts at the starter wire? I don't have a voltage drop issue because I have confirmed the starter will start the engine if I jump the solenoid.

 

I would try replacing the starter relay. Even though you tested it, it might not be passing enough current to the starter solenoid. Its a cheap and easy thing to try. Those relays can be had from any late 90's Toyotas (Camry, Corolla, etc) at the wreckers. I always carry spares of those important relays (starter, EFI, etc). I believe the part number is 28300-10020 .

 

This is what I'm leaning towards since its a cheap part at the junk yard.

Thanks for the help! I will report back with the results.

 

Sounds like a bad wire connection from the relay to the solenoid or power supply(whatever that may be) to the relay. Not allowing enough current to trigger the solenoid, but still showing battery voltage. Or the relay.

 

That is also a good idea. I will have to check the wire connections at the relay.

 

Update. I finally got the truck running again. The starter relay turned out to be the culprit. Although my old starter relay seemed to be working and I was getting power to the starter signal wire, it wasn't enough to jump the solenoid.

I'm just glad its running again. Thanks for all the help guys!

 

Where is the starter relay loctated?

 

Its in the under-hood fuse box (labeled 'ST').

 

If it overheats the relay again, you might need a whole new starter. Carry a spare relay. There should be a unused/unwired spot to the right of the ST relay to put one there. When the starter stuck on you,,it could have put quite a bit of heat thru those contacts,,2 weeks worth of life after that.