Starter repair on 96 Corolla

[GSS123]

I usually hang out more in the Camry forum but I do have one Corolla. I thought I would post my recent repair of the starter for other shade tree mechanics.

I have a 1996 1,8L 7A-FE engine, 5-speed manual transmission with just a tad over 180,000 miles. During early August I noticed the starter would have a slight pause before pulling in the solenoid. At first I thought it was the safety switch that is activated when the clutch is fully depressed. I ruled the switch out with my testing since I could hear the solenoid click when the ignition was turned to the ON position; therefore the clutch safety switch was working. Eventually nothing would happen when I turned the car on except for a single click or sometimes just a hummm sound.

Reading the FAQ section I found a description of my problem and decided to rebuild the solenoid by replacing the old contact with new contacts. New contacts from my local Toyota dealer are $6.50 each and two are required. A new starter is $176.00 from the same dealer. I didn’t ask them what their charge was for replacing a starter. But the part counter manager said they usually rebuild the starters instead of replacing them. I was surprised at this, knowing they would have to stand behind their work if the starter crapped out again say in 3 months. Their labor rate is $90 per hour. I figured they would go with new starter just as a CYA move.

First problem I encounter with removing the starter is my Haynes manual for 1993-1997 Corolla's & GEO Prizm's is way off base. In my case you need to remove the battery and the Air Cleaner housing. In the Haynes manual they say you need to remove the battery and cruise control assembly from the engine compartment. I think this is a misprint? The cruise control assembly is near the timing belt side of the engine and the starter is near the transmission side of the engine.

So after tossing the Haynes manual to the side I proceeded removing the battery and air cleaner housing. Next I raised the car about a foot off the ground and made sure it was blocked up and safe to crawl under. I then doubled checked my blocking and then checked it a third time before crawling under the car.

Next I disconnected the electrical connections from the starter. One connection (coming from the battery) needs a 12mm socket or wrench. The other connection (coming from the ignition) is a plug type; you’ll need a screw driver or something to press a raised nub of plastic down so you can slide the connection apart.

Place these wires aside and take off your coat and any heavy sweaters you have on because this next part requires a very thin arm and about a triple jointed elbow. Reach up between the axle and suspension cross member to place a 14mm socket on the lower bolt holding the starter to the bell housing. This is a pain in the A_ _, but after several socket wrench extension changes, relocating the wrench a half dozen times I got the bolt out. Really only took about 30 minutes, but working on the garage floor and reaching for a tool is a whole different world then what a professional mechanic works in.

Next get out from under the car and go up on top and remove the top bolt holding the starter to the bell housing. You'll have to move a portion of the main wiring harness out your way but there's enough slack in the harness. After the second bolt is out I just let the starter fall, the pros are now shaking their heads at this I’m sure??? The starter falls down and is caught on the axle and suspension cross member. Get back under the car and work the started toward the passenger side fender skirt. The skirt is plastic and it will move out of your way far enough to pull the starter out.

Replace the solenoid contacts; I used information provided in the FAQ section.

On reinstalling the starter I don't see how one person can do this job. So I drafted a family member to screw the upper bolt in after I got the starter in place from underneath the car. Then I put the lower bolt in, reconnected the wires to the solenoid, and attached the air filter housing and finally the battery.

Started right up just like brand new corolla. Total time including putting the car on stands, installing the contacts and cleaning up the starter housing 4 hours.

[wrightz28]

Wow, all that

I miss my Buick already, no real need to jack it up, and takes a half hour taking your time.

[Brian R.]

Good post. I'll put this in the FAQ thread.

[SpinnerCee]

Excellent How-To

I have a similar issue on a 95 Corolla w/4A-FE w/~70Kmi.-- turn key to start: click, again: click, again: click, again: vroom --- has been occurring for about 6 months, I assume the click is the solenoid "kicking in", but because the high current contacts are worn or dirty, the starter cannot get enough current to actually turn the starter.

I also checked the usual suspects like the battery, wiring, and relays -- You're also super correct that the Chilton "authority" was of no use here -- it does not even have a single diagram or photo to help you find where the darn thing is located or what it looks like!

I finally found the starter by feeling around underneath the intake manifold, and found some very heavy grease underneath the solenoid -- this is possibly part [a symptom] of the issue? I guess once all that grease or diletric stuff gets pumped out, the solenoid may become more succeptable to moisture and the contacts may begin to oxidize or just plain corrode?

Thanks for the DIY -- now I can tackle this issue for real

[GSS123]

SpinnerCee........You described the symptoms I was having.

Your not going to like what I believe the source of heavy grease is on the starter. The "u-joint" boot on your half axle is loosing grease. The passenger side half axle seems to fail more often then the other side. Mine did this and the rubber boot looked like it was in excellent condition. I had to replace the half shaft with a factory rebuilt unit. On my car I speculated the rubber boot opened up from centrifugal force when turning a high speed. I could not find a break in the boot even after the axle was off.

Over time you may notice a vibration like your front tires are out of balance at just one certain speed. Mine was very noticeable between 59 mph and 63 mph. But nothing at speeds over or under.

My starter was covered with this heavy grease, which I cleaned off during my repair of the solenoid contacts.

BTW thanks BrainR for the complement. You and a few others have really made working on my Toyota's fun for an old fart like me.

[Brian R.]

You're welcome.

[bwahna10]

Thanks a ton for the detailed steps GSS123!

But for your notes I would not have been able to take the starter out! The Hayes manual leaves much to be desired on this one!

Now that I got the starter out, I am trying to see where I can buy the contacts locally in the Seattle area. Anybody know?

Another possibility is to replace the solenoid switch. That part is $100. But I am not entirely sure how to remove this magnet switch from the starter motor. I see 2 screws on the inside that seem like philips, but are too tight. Do you think it is worth changing the whole switch and if so how does one do that?

Thanks a bunch!

[GSS123]

Bwahna10........ I found contacts at my toyota dealer (BTW take the contacts with you they have several types) and have since found them at a local auto electric repair shop. If your problems is the same as I had then just buy the contacts and follow the detailed instructions in the FAQ's

Post back and let us know how your project worked out.

[crazeedrivr]

I don't know much about cars but it sure is appreciative when someone takes the time to write about their experience to help others. I do have to say that my corolla wouldn't start last fall and the Toyota service dept. said it was the starter contacts. Which instead of even asking me whether I wanted them rebuilt or the starter replaced , they just went ahead and rebuilt the contacts. Cost me almost $400 dollars to do (no joke) then another $350 to fix the cable that unhooks the hood. It went bad and what was I to do it was already there and I had to get it home after they fixed the starter problem. Sad thing is it didn't fix the starting problem. So I called the serv. dept. and ask what does their work guarantee, well his reply was well of course we will only cover the contacts that we rebuilt for you. The guy was extremely rude . So to say the least I haven't returned to that dealership and never will! My mom used to own a car shop in a small town so she always thought it was important for a woman to know a little about cars , but I also notice being a woman that men at the serv dept. seem to talk down to me when I express I know a little about cars why is that? So to all you husbands out there , go take your wife out to the garage and teach her something if u already havent done so!

[bwahna10]

Originally Posted by GSS123

Bwahna10........ I found contacts at my toyota dealer (BTW take the contacts with you they have several types) and have since found them at a local auto electric repair shop. If your problems is the same as I had then just buy the contacts and follow the detailed instructions in the FAQ's

Post back and let us know how your project worked out.

Sorry about the delay in replying. No news is great news in this case!

I got my contacts at the Toyota shop for about $30. My Haynes manual cost $20. My car jack cost $20. All up the cost was $70.

The quote I got to get it done was $600. In otherwords, YOU saved me $530!

Even if you include the cost of the new battery ($60) I got while trying to eliminate possibilities, I think I came out ahead!

Haven't had any problems for the last 2 months. And even if I do have problems, I now know what to do.

THANK YOU!!!

[famlycar]

A carload of thanks to all of you for this thread. It''s just the info I needed to convince my wife not to take the car to the dealership for repair. I'm going to print this out and paste it into my Chilton manual.

[Copytech99]

Don't forget to clean up the solenoid plunger when repairing these.

[famlycar]

Well, I finally got some time to work on my starter last week. I bought the contacts for 50 dollars. I had the starting problem happen three times on the day before I was going to work on the car.

I raised up the front of the car and supported it. Removed my front passenger side tire and air cleaner housing and then got under the car to remove the electrical wiring to the starter. Although I can see the starter very well but it certainly is not easy to reach. I noticed two connections there; one a kind of ground wire connected to the engine and the other under the starter with a plastic cover protecting the nut (both nuts are 12mm). I loosen both nuts just to the last threads when I decide I'm going to have to get more tools to complete the job. So, I replace everything back to where it was. I decided I was going to complete the job the following weekend. But, ever since I just loosened those two nuts and screwed them back tight, I have never had any problem with my corolla starting!!?

I guess just loosening those connections was all it took to solve the problem. I don't know but it has been a week now with no more starting problems.

[Copytech99]

^^^^ It could have been a connection problem.... Or the plunger may be currently in a good area and will eventually show problems again. The nice thing about this problem in most cases it won't leave you stranded.

[famlycar]

The info above (at the top) is exactly what has to be done though. I was sitting down for about 15 minutes peering in through this six inch hole on the passenger side tire area just wondering if there was any easier way to get to that starter and all!!! So, am I ever thankful I don't have any more problems!!

I can understand what Wrightz is saying about his buick now.