Starting issue after transmission repair

I recently (last week) removed my trans and put it back. I took a few tests drives and things seemed well. I decided I was going to start using the truck again (it had sat for a few months waiting for my decision to do trans) it had gas and my suzuki sidekick was acting a little funny.
All things where going well for A DAY. On the day I needed it the most (I had to do a lot of kid rodeo- round them up moving them about, etc) I pulled into my garage (first mistake that is my wife's spot). I went to head out for next round of kid rodeo and it would not start.
All lights came on as well as radio when turning the key, but nothing from the engine. I tried using the 'no clutch start' button, same thing all lights, no start. No click, nothing. Back to the suzuki.
Today, I read a few threads from here and replaced battery. No change. No noise at all
I tested the starter relay, it did what it should on the bench.
I looked/checked fuses. All good.
After putzing with the above, on a whim, I depressed the clutch switch by hand and tried to start, and oops I should have had it in neutral because it lurtched forward... It was going to start!
I got in the seat, depressed clutch, turned key and it started! I am HAPPY.
for only a short time.....
Remember, I just pulled the trans? Well I had put the 4 wheel drive shifter in incorrectly. I had the thing slanted left and not right, so when I went into second gear I would hit the 4wheel drive shifter. (my bro has similar truck and I had him send me a photo of his in 2nd gear)
So, I work on switching that around. I am not getting it to be able to shift. So I move car out of garage, drive back and forth a few times. Stop, turn off truck (in front of garage door-oops) and again, it will not start.
No click, all lights.
I test relay again, clean up all terminals, double check all fuses. Wiggle wires. Smoke to many cigarettes, etc.

I am stumped and need advice

(sorry, if I am a little winded in this, I have seen to many threads with not enough info, and then when more is revealed, the solution is. I want as much out there as possible to get it right quickly, the suzuki is needing my attention)


A little background:
I need to send a HUGE shout out to allmotorrex and his page on clutch replacement. My used 2003 Tacoma SR5 had the clutch release fork break. While in there, I decided to replace clutch, throw out bearing, pilot bearing (big mistake) the other thing I can not remember the name of. All things went smooth enough for a novice like myself (getting that trans back up and in by myself with no trans jack was an ________ (you fill in the blank))
All things went well.

 

First thing's first... does it make a "click" when you turn the key to start? If so, then it's the copper ring/contacts in the starter not contacting. The solenoid pushes the output shaft to the flywheel and when at full extension the ring bridges the two contacts, which is where the juice to run the starter goes through. This can be rebuilt for a few bucks. I've had mine apart to clean it, two years so far and the issue hasn't returned.

If there's no click, then I'd be taking a close look at all the external connections, particularly the small signal wire that gets current when you turn the key. If memory serves it's just a small plastic connector that could easily get corroded inside.

It's very unlikely to need it, but I suppose you could grab a used starter if other troubleshooting fails. One nice point about the four cylinders, even the 2015s use the same starter that Toyota used in camrys and such 25 years ago, so they are plentiful and cheap. Just cross reference on car-part dot com to see

 

I'll second what he says ^^^. Good advice.

 

Update:
I checked checked and cleaned up connectors. I tested the signal wire from starter relay to starter and it was getting the battery voltage when I 'started'. But the starter did nothing!
A few times during my checking and cleaning, it would start, only to not start the next time I tried. Again, when it does not start, there is NO NOISE, NO CLICKS. When it did start it sounded as it should, very clean start. I would try to repeat what I had just done and fail.
I did get the 4 wheel drive shifter in correctly. Is there a switch in there that controls starting? I cannot see it on the wiring diagram.
I made the decision to remove the starter, what a challenge. Disconnecting was a breeze, removing was the challenge. It tested good repeatedly at the auto store.

What next? What am I missing? The signal wire connector from relay looks good. No signs of corrosion inside.

 

Get yourself a piece of wire roughly the same gauge as the thin wire that runs the solenoid, and an inline fuse. Hook the fuse up as close as you can to the battery, run a wire from the fuse *into the cab*, and another wire from the starter solenoid to the same place in the cab.

When you connect those 2 wires together, it should crank the engine. Maybe add a push button switch.

If this bypass works reliably to start the engine (as I suspect it should), then your problem will be somewhere in the wiring, or the key switch itself.
If the bypass reliably CRANKS the engine, but it doesn't start, then you are dealing with a problem with the supply to the ignition switch.
If the bypass *does not* reliably crank the engine, then there is a problem with the solenoid or starter motor or the GROUND, or the big wire from the battery to the solenoid.

 

Update 2: After checking all wires, connections and fuses and removing the starter, I cleaned up the connectors inside the solenoid as
ItalynStylion showed on his wonderful write up. Mine where not as bad as his but came out just as shiny.

I had it tested again at auto store. Re-installed. And all is well. Magic.