I’ve spent about 20hrs troubleshooting an intermittent “no start” issue. After going through all of the diagnostic steps 3 times to condemn a starter. I finally pulled it… here’s what I found.
When I started the engine rebuild, I bought a Toyota remanufactured starter from Stevinson. Unfortunately my brain just wouldn’t let me condemn it, so I kept looking elsewhere. I finally pulled the “new” starter and found that during the Re manufacturing process, the rebuilder replaced the contacts, but not the plunger. This lead to very little contact and an intermittent no start.
I didn’t have a set of contacts on hand, so I put the old plunger in the lathe and carefully touched it up.
She starts like a dream.