Starting Problem on "66 Toro

[Otto Skorzeny]

Saturday morning, with no prior problems or hint of any, my car would not start.

The solenoid clicked but the starter would not turn over. The car had been driven the day before and had started without issue at the first turn of the key. Starter turns strong and car starts in a split second.

After a couple tries with nothing but a click I tested the battery and found it to be at full 12.8 charge. Cables are new, clean, tight, no corrosion anywhere. This includes the ground wire to the block which is tight, new, clean and attaching point at block is wire brush clean.

I checked the connections at the doohickey in the photo and they were also tight, clean and not corroded. For the heck of it I whacked the silver thing with my knuckle and gave the switch another turn.

The car started instantly and I thought that something at that connector must have been loose so I planned to take it all apart and clean it.

I did just that, cleaning the stud and all the terminal ends that attach to it. I also cleaned the two prongs sticking out of the rectangular metal thing.

Well, the car started fine and I figured that was the end of it. Today it did the same solenoid clicking.

I found that if I turned the key quickly to start and then released it I could hear the car almost turn over and then it would start on the next try.

First: What is the thing in the photo? FSM is vague on it and the diagram does not really match the appearance of this thing but it says that one of the wires is the main harness feed and that the other connector is a horn feed. Is this correct? The other two cables, of course are the cable from the battery and the cable to the starter.

Could this thing be the source of my problem? What is that silver thing? It looks like a switch or solenoid or something.

When I tapped it on Saturday, was it just a coincidence that the car started afterward?

Second: If that thing isn't related to the starting circuit, where might I look next? Ignition switch on dash? Starter solenoid?

I intend to disconnect and clean all the connections at the starter but they are all tight and look corrosion-free.

[Otto Skorzeny]

This morning I cleaned up the connections at the starter. There was nothing amiss but I cleaned and tightened them anyway.

No luck. The solenoid still clicks but the starter doesn't turn.

I bypassed the junction in the photos with a single cable just to see if it made a difference. It did not. I can't even coax the engine to start by flicking the key on and off. This seemed to work the other day.

I rapped the starter with a rubber mallet to see if it was hung up but that didn't work either.

What say you? Is the starter kaput?

[bluecab]

Sounds like its the starter.
I'd take it out and bench test it.
Starters are easy to get and / or rebuild.
The contact points in the solenoid get pitted long before the motor stops spinning.
Also check the ground path from the block back to the battery, the original block - to - chassis ground was pretty lightweight.

[Otto Skorzeny]

Well, I tried whacking the starter with a rubber mallet and that tended to make the car good for one or too starts before requiring another whack.

Since the starter engaged quickly and strongly I set my sights on the solenoid. I figured that disc in there was corroded or not making contact with the two studs.

The disc is dirty but not badly corroded but as you can see, the contact point for the big battery stud is burned away.

I rotated the contact point 180* and wire brushed the disc.

We'll see what happens when I put this thing back together.

[Otto Skorzeny]

Here's the contact disc after cleaning.

[Otto Skorzeny]

I got everything put back together and buttoned up.

It started on the first try and 7 or 8 starts after that. WooHoo!

That solenoid (the factory installed one) oughta be good for another 100,000miles of starting pleasure.

[Checkov]

I'm not sure about the metal box either. My guess is a voltage regulator, I had to replace one on an early model Datsun hehe it looked a little like that.

[bcroe]

my car would not start.

What is that silver thing? It looks like a switch or solenoid or something.

When I tapped it on Saturday, was it just a coincidence that the car started afterward?

I am pretty sure the silver thing is your horn relay, which in some years also
served as a key buzzer. Good work on the starter so far, but I wonder if you
checked the brushes? Bruce Roe

[67_Toro]

Gonna have to try this on my 66 too. I had the same symptoms, started fine from the key every time, now nothing. No crank, no horn, no dash lights, no blower. It does, however, have wipers, blinkers, interior lights, window power and antenna power. Starter will come out this weekend for some attention.

Thanks

[Otto Skorzeny]

Good luck. Make sure your battery cables and all connections are clean and tight with no corrosion.