80 Series Starter Motor

Submitted: Monday, Jun 09, 2003 at 11:22
ThreadID: 5352 Views:4286 Replies:7 FollowUps:3
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To any auto-electrical experts out there!

I have been having a few instances of having the starter solenoid click and no fire - try again once or twice and away she goes. No this was not very good considering we are in Canning Stock route setup mode.

So I pulled the starter motor out of the vehicle yesterday. My trusty Gregorys indicated that it was likley to be dirty contact in the solenoid. I pulled the cover off the solenoid and removed the center pin (the actual solenoid relay center pin). This drives the starter motor gear in and also makes the electrical contact between two (brass, bronze or copper contacts). No I noticed that one of the contacts has worn and lost about 2-3mm of the contact material. I removed this little piece of metal (to see what it looks like) and it is a little right angle about 2cmx2cm using about 5mm material.

I need to get a new one of these - is this a Toyota part or should I go to a metal shop and fabricate my own? I have a digital photo of this part if that will help get the answer to my question.

Just so you know I cleaned the contacts and filed them - put it back together and it is working better than before as it fires ever time however I want to replace the contact to ensure that it continues to work for a lot longer.Regards
ExplorOz Team - David
Always working, not enough travelling ;-)
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Reply By: Peter L - Monday, Jun 09, 2003 at 11:30

Monday, Jun 09, 2003 at 11:30
David, I had the same proble with mine some years back. I don't recall mine being a right angled contact but I do recall that I replaced it (them) upside down - no trouble for at least 4 years.
Have seen the matter raised on other forums and apparently non-genuine replacements are available. Not sure where but try an auto elec to start (pun intended). Others on this list may have more recent experience (or a better memory)

Great site - Great forum.

Peter L.
AnswerID: 22114

Reply By: crfan - Monday, Jun 09, 2003 at 12:53

Monday, Jun 09, 2003 at 12:53
Hi David,
You will fine most auto electrical shops will have these bits in stock
you could take in the solinoid it to them and have the fit the contacts or just buy the off them and fit them yourself.
AnswerID: 22116

Reply By: Bob Y. - Qld - Monday, Jun 09, 2003 at 13:07

Monday, Jun 09, 2003 at 13:07

The HJ60 & early HJ75's had this problem after some use. I took a number of vehicles to sparkies in the Isa, and they would fit h/duty contacts. End of problem.

Our HJ60 got so bad, on an intermittent basis, that carried a screwdriver under the d/seat to short out terminals on solenoid. Like 5am on driveway at Shell in Dalby Q, on the back with no torch trying to see the correct terminals.

Have a great trip up the Canning. Hooroo...

AnswerID: 22118

Follow Up By: Member - Rohan K - Monday, Jun 09, 2003 at 18:47

Monday, Jun 09, 2003 at 18:47
Hey Bob, I used to have to play that game on both my FJ40s. (You should have seen the chunks eaten out of the screwdriver from the arching.) Sounds like a weakness that Tojo still hasn't soted.Talk is cheap ...
Rohan (Sydney)
FollowupID: 14532

Follow Up By: Member - Rohan K - Monday, Jun 09, 2003 at 18:50

Monday, Jun 09, 2003 at 18:50
Oh David, I forgot to mention, I solved my problems with a couple of dirt cheap starters from a wreckers. I pulled them both apart, used some parts to repair the one from the vehicle and used the rest to build a spare starter, which I did end up using.Talk is cheap ...
Rohan (Sydney)
FollowupID: 14533

Follow Up By: Bob Y. - Qld - Monday, Jun 09, 2003 at 21:05

Monday, Jun 09, 2003 at 21:05
Yeah, Rohan, I've still got a scewdriver like that too. Has lost the burn marks but you would need a vivid imagination to call it a s'driver.

We've had no starting probs with last 2 80 series, but don't do any stop start work either. Hooroo...

FollowupID: 14546

Reply By: Member - Martyn (WA) - Monday, Jun 09, 2003 at 22:08

Monday, Jun 09, 2003 at 22:08
Don't mean to be a smarty but have you ever considered a NISSAN........... End of problem, good luck on the CSR.Keep the shiny side up
AnswerID: 22159

Reply By: rolux1983 - Monday, Jun 09, 2003 at 23:02

Monday, Jun 09, 2003 at 23:02
comman problem with the diesel hilux of mine,purchased mine from auto pro (S.A) and keep a spare set in me breakdown box.easyjob to do just make sure you press the solenoid plunger down onto the new contactors when tightening the nuts that way the touching surfaces square themselves up.have fun.
AnswerID: 22161

Reply By: Smithy - Tuesday, Jun 10, 2003 at 12:26

Tuesday, Jun 10, 2003 at 12:26
Your on the right track, altough I wouldn't recommend sanding the tips. They're made with a special coating and though it may look as though it has worn off it'll still be there. It's ok to sand them to get you out of trouble but I'd look at replacing them soon. The coating is to reduce the amount of arcing between the contacts. Just replace the contacts, you can get them from any auto elec, or car decient car part supplier, or better yet call the supplier or maker ie Bosch, etc. Clean all the crap out of it and should be as good as new. Might want to replace the brushes, clean the comm, clean the stator from carbon dust, etc, and replace the bearings while you've got it apart. Doesn't take long, and that's all you'll get for a service anyway.
Cheers and Good Luck
Shift Sparky
AnswerID: 22192

Reply By: Member - Andrew- Tuesday, Jun 10, 2003 at 13:17

Tuesday, Jun 10, 2003 at 13:17
You need to buy a new contact, it is funny how only one wears, but 1 is all you need to buy and clean up the surface of the plunger aswell.
Aftermarket ones can be got for a few $$ and have longer contact areas to assist in future.
AnswerID: 22200

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