Offroad-Express

Evening Folks
This is my first post on Offroad Express, although I know a few of the regulars here.

I have the usual Toyo clicking relay problem on my SWB 93 Prado which developed whilst I was away for seven months in Antarctica. Initially I thought it was flattish batteries (my truck runs the twin sytem), then when I got home figured it was dirty connections from the batteries. Having cleaned all 4 battery posts and clamps, the problem still exists. The problem is only intermittant and thus far when the clicking starts the starter motor will turn over after 5 or 6 key turns. I figure I am going to have to rebuild this unit.

My Questions are;
1) What is the likely fault?
2)What, if any special tools i.e. bent spanners etc, will I need to get at the top starter bolts?
3)Can I seal the starter motor unit in any way to stop mud getting into the relay?

Thanks in advance
Cheers John

I had this problem and just replaces one battery and now it starting mint, are you getting enough amps from your batterys

Thanks I will check cranking amps tomorrow
J.

12 or 24v? I guess its 12v as I dont know of any 24v prados...

stick a multimeter set to Volts on the + and - of the batterys and get a mate to read the result when you crank it, if its below 9V then you'er not getting enough power...

Have you clean all the earth leads - where the battery connects to the chassis, and from the chassis to the engine. I went through the same drama, & all it needed was to take off all the earth connections, & give them a clean up, & no problems since. Cheap too! Pity I overhauled a perfectly good starter before checking the leads....

yer had the same prob with the starter on my surf, it had dirt and crap in the solenoid, gave it a couple of taps on top of the solenoid and it went, but ended up getting a second hand one of tomsoffroad, it was going to cost me between $240-320 to get it fully rebuilt, try looking on trade me or some one on this site mite be able to help

Thanks all for your replies
Well I pulled the starter off today, 1 x 17mm socket and a long powerbar was all I needed. The biggest drama was releasing the plug from its socket for the wires from the ignition switch, very tight.
One of the contactors was worn almost completely away whilst the other was nearly new. This is normal according to my tame autosparky.
$28 later for 2 new contactors and it was working fine.
I then took the opportunity to tap out the two air vents (1 on the solenoid and 1 on the motor housing) to 1/8 BSP so I can connect these air vents to the extention diff breather hoses. Finally I reassembled the starter unit using lurethane sealer around all joint surfaces. Hopefully no more water and mud in this in the future!
Cheers John