Hilux wont stop cranking!

[Slayer]

.. I put this in auto elec section first, but then figured id get more hits here so if the mods want to deleat the first post, then thats cool. Anyways Started having this problem last week and has happened twice now, go to start my lux and it fires up but the starter doesnt disengage and so it makes that horrible sound when the clucth is doing overtime in the starter. Naturally i turn the key off straight away, only to find this cuts the fuel, the engine stalls (90' mod 2.8 diesel) but the starter keeps cranking. Only way i can find to stop it in a hurry is grab a spanner and undo the battery terminal.
Starter motor is only 12 months old. I thought the ignition barrel may be sticking, but all other IGN activated things go off with the key, just that the starter keeps goin. None the less i sprayed some crc down the barrel.
Just happened again so i took the starter relay out and filed the points, although they looked fine, as new inside!

anyone had this happen before? could it be a starter motor problem? I figure power needs to be getting to the swicth wire on the starter when it shouldnt be, so im looking further up the line.. ie relay or ignition barrel
thanks for any heads up!

[killalux]

hey, have seen this prob a few times, the solonoid contacts in the starter wear and start arc-ing, sometimes they melt themselves together, causing the starter to hang in. pull the starter off and replce contacts and plunger.

[PGS 4WD]

What killalux said is spot on but also consider fitting a start relay if the vehicle dosent have one already, the contacts in the solenoid burn when they aren't engaged solidly, if the wiring or ignition switch are offering resistance to current flow, then the solenoid dosent throw in firmly and the contact burn.
Joel

[HIL01X]

Had the same thing happen to our 4wd with a 903 cummins. Turned out the battry voltage was low causing the starter soliniod to arc and weld together.

Oh yeah, it,s a 4wd tractor.

[ferrit]

hey, have seen this prob a few times, the solonoid contacts in the starter wear and start arc-ing, sometimes they melt themselves together, causing the starter to hang in. pull the starter off and replce contacts and plunger.

Thats what killed ours- but ours also wedged the starter gear against the flywheel, so by the time we had driven it the 5km home from CFS training, it was absolutely fried!

[Sic Lux]

Yeah i'd say sticky soleniod aswell but have you lubed the shaft up and made sure there isn't anything on there causing it to fowl/stay out but if thats all good i'd say your up for a soleniod or is it still under waranty.

[Slayer]

thanks for the heads up people. will pull the starter out and have it looked at asap, id say it would be out of warrenty as its closer to 18 months old now, but none the less u wouldnt expect it to happen. the car has not done alot of work in that time either!
is this something that some emery paper and crc will fix? or should i be considering stripping it down and replacing parts?
cheers

[killalux]

mate, the parts are only like $30, so i would replace them.

[STUMPY]

Not hard to do, i did it last week.
http://www.4x4wire.com/toyota/maintenance/starter/

[cloughy]

Could also be a worn ring gear

[Slayer]

bit of an update on this.. after using several methods to test and illiminate either the ignition barrel or the starter relay i went on to pull the starter and find the contacts in the solinoid almost perfect, no wear at all like the ones in stumpys link.. i gave the contacts and the plunger thing a light file and re assembled with high hopes only to find that it stuck EVERY time now!... worse than before!..
pulled the motor again and this time pulled the gear off the front, then the reduction gearsets and then the soliniod winding. found it to be fried pretty well and it looks to be becuase of a lose conection where the ign wire goes into the winding.. not sure if its viable to replace this winding because parts are prob more than a new starter.. anyone replaced the solinoid winding on one of these before?

[Gribble]

Happened to me about 2 years ago, remove starter, pop open the solenoid and pull out the contacts, go see an auto elec and for an easy change of $20 should see you with some nice new clean contacts (if you fit them yourself of course). BUT, also check that the clutch and motor havent been stuffed up before you chuck the starter back in. But if its a factory denso starter it shouldnt be busted unless it was running for 10mins.

Its probably also a good idea to make sure you havent got a voltage drop in the starting system either as lower volts can mean extra amps.

[Slayer]

Happened to me about 2 years ago, remove starter, pop open the solenoid and pull out the contacts, go see an auto elec and for an easy change of $20 should see you with some nice new clean contacts (if you fit them yourself of course). BUT, also check that the clutch and motor havent been stuffed up before you chuck the starter back in. But if its a factory denso starter it shouldnt be busted unless it was running for 10mins.

Its probably also a good idea to make sure you havent got a voltage drop in the starting system either as lower volts can mean extra amps.

Thanks for the help mate, but you either didnt see my last post, or are plain stupid... turns out the contacts are as new, and its the windings in the soninoid that are fried... dont think handing 20 large to mr auto elec will see this out...

[Sic Lux]

best bet go talk to the auto elecy and see if he can get the part or a whole new solinoild i'd say it would be doable but as have a good mate who's one and he can get most of that sort of crap.

[killalux]

replacement windings are available, not a simple fit though. would prob look at a second hand starter.

[Slayer]

have my old one back in there atm.. was told by the auto elec 18 months ago when i replaced it that it was 'compleatly shagged mate' ' best bet is to get a new one'.. anyway ive fitted the perfectly good contacts out of the new one into the apparently shagged old one and its working fine. reason it was replaced originally was the click click click start problem like so many have had!
anyways im out of trouble for a while, but may look at getting parts for the stuffed one as long as the price is right
thanks again for all input

[Slayer]

replacement windings are available, not a simple fit though. would prob look at a second hand starter.

if replacement even closly resembles the reversal of removal then i cant see it being too hard. the ign wire requires soldering once in location, and the 2 push through clips need the taps flairing out to hold it steady.. apart from that id say a monkey could be trained to do it. ill be giving it a go anyhow and ill report on how it turns out!