Tried everything - Tacoma still won't crank...

(1997 Tacoma 2.7 L 5 speed 4 WD regular cab )
Okay, I'm completely out of options, so I hope you guys can help...
I get one loud click when I turn the key. There wasn't any warning , was running great ( as always) and then this. So, started out by replacing the starter, but that didn't help... checked the battery, and that tested good (12.51 volts), but ended buying a new one just in case the cold crank amps weren't enough. Cleaned all battery connections. Tested the alternator, and it's good with 14.18 reading with engine running and high beam lights... at 1500 rpms I get a steady reading of 14.15, and 14.22 with the lights off, and that was on the old battery. I have tested the starter relay, clutch start switch, negative,positive and ground connections to starter, and they are all good. I even opened up the new (refurbished)starter to make sure the contacts were good, and they only show minimal wear. I don't know where to look beyond this point... one more thing - the truck fires right up with a push start, and runs great!

 

Ignition switch?

 

One thing to check that could be bad. Pull all spark plugs and see if it turns over. I blew a head gasket on an old chevy astro and it hydro-locked after I parked and the steam pressure filled a couple of cylinders with water. If it blows water like a sperm whale, you will know what the problem is. You might not like it, of course, it is not a 50 dollar fix...

 

He says it fires up with a push start, don't think that's it.

 

It turned out to be the positive cable from the battery to the starter. We had tested it for continuity, and it checked out, but since it was 17 yrs old we decided to change it out anyway. The truck fired right up! Bought this truck new in November 1997, and wouldn't take anything for it.

 

Turned out it was the positive cable from the battery to the starter. Even though we had tested it, and it had continuity, we decided to change it out anyway due to it being 17 years old. The old wire just wasn't strong enough to carry a full load to the starter. The truck is running like a champ again!

 

Good catch. We all tend to overlook the battery cables. Voltage drop testing is an excellent way of finding cable or terminal corrosion problems. Normally it would have been the solenoid contacts/plunger. They take quite a beating every time you start your engine.