TLC Starter motor contacts replacment fix

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TLC Starter motor contacts replacment fix

Post by Homer » 21 Dec 2017, 2:47 pm

G'Day Fella's,

For some time now, I have been having problem starting my 1990 vintage L/Cruiser.
This only happened very occasionally but usually when you least wanted it to happen.

I spoke to a bloke I know at The Battery Factory, here in Canberra, and he suggested that it may be the starter motor contacts.
Rob also said that these contacts get eroded away from arcing, during the starting operation, and eventually need replacing.
So a few weeks back, I got to it and pulled the starter motor out,
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Rob also suggested that it is a fairly straight forward job to replace them, and told me where to get some replacement Contacts and Plunger from.
This was not quite as straight forward as that, as nobody had the exact replacement parts, not even Toyota.
The original contacts are made from 2.95mm thick Copper.
So I managed to get some similar shaped Contacts (but only 2.45mm thick), from an Auto Electrician and a new Plunger from another supplier.
I then went about machining away the stepped part of the smaller contact, leaving only 0.5mm remaining, on that area that makes contact.
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I then hack sawed off the contact section of the replacement 2.45mm thick contact I had, and Tig welded it to the original and machined down contact.
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After this was all completed, I soaked the repaired contact in Copper Bore solvent ("Patch Out" brand), which cleaned it up.
I then rinsed this solvent off and reassembled the starter motor, and bolted it back in.

It works as good as it did, when the "Battle Cruiser" was new.

Hope that helps

Merry Christmas
Homer
Last edited by Homer on 22 Dec 2017, 4:49 pm, edited 1 time in total.
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Re: TLC Starter motor contacts replacment

Post by darwindingo » 22 Dec 2017, 12:04 am

Nice work Homer, the contacts and plunger are about all that will ever fail on them... Nothing like fixing stuff your self :thumbsup:

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Re: TLC Starter motor contacts replacment fix

Post by VICHunter » 27 Dec 2017, 3:31 pm

Looks the business mate.

I saw your post with the DIY sidesteps in the other topic too.

Putting out some winners in the workshop there :)
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Re: TLC Starter motor contacts replacment fix

Post by marksman » 30 Dec 2017, 9:54 pm

I really like to see things repaired and not thrown away :thumbsup:

good on ya Homer :drinks:
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Re: TLC Starter motor contacts replacment fix

Post by Homer » 31 Dec 2017, 5:36 pm

G'Day Fella's,

Thanks for your kind words.

Best Wishes to you all, for a great 2018!
Homer
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Re: TLC Starter motor contacts replacment fix

Post by Norton » 18 Jan 2018, 3:29 pm

My starter has been getting sluggish lately too. Now I know who to call when she carks it :mrgreen:
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Re: TLC Starter motor contacts replacment fix

Post by Homer » 04 Feb 2018, 8:30 am

Thanks for the vote of confidence Norton.............. but no thanks Cobber. LOL!

Regards
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Re: TLC Starter motor contacts replacment fix

Post by Roo farmer » 04 Feb 2018, 9:40 am

I hate to tell you, but I have put new contacts in two different Landcruiser starter motors. Both were a perfect fix for about 6 months before failing badly. In both cases, the copper plunger disc shifted and shorted out on the side of the housing and burned through the solenoid coil wire, and the dead short killed the battery as well.

So instead of spending $400 on a reman starter from Toyota, you spend $60 on contacts and plunger, then 6 months later you spend $400 on a reman starter, $200 on a new N70ZZ battery, and $50 on new battery cables.
I can't see that I fitted anything wrong, it's pretty much impossible to fit the plunger wrong. This has happened to me twice. First time I thought it was bad luck so tried it a second time. I don't think I will bother again.

The place that sells you the plunger will have fitted heaps of them and never heard of this happening.
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Re: TLC Starter motor contacts replacment fix

Post by Homer » 04 Feb 2018, 6:00 pm

Thanks for the heads up on your experience Roo Farmer, I'll keep this in mind.

Regards
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Re: TLC Starter motor contacts replacment fix

Post by Roo farmer » 04 Feb 2018, 9:26 pm

What model Landcruiser do you have? The contacts are slightly different than the ones I have, on 1HZ engines in 75 and 79 series Landcruisers. Mine have same plunger but two contacts opposite each other like the one on the left in your picture. I haven't seen ones like the long curved one on the right.
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Re: TLC Starter motor contacts replacment fix

Post by Homer » 05 Feb 2018, 7:16 am

Roo Farmer, my BJ73 TLC has a 3B, 3.4 liter, 4 cylinder diesel engine in it.
In trying to locate replacement contacts (no longer available from Toyota), I seen all kinds of shaped contacts at Auto Electricians.

Doh!
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