Anyone else have starter/relay issues with a Gen. 3? Curious if anyone has experienced a similar problem.

[Skidmarkart]

Okay, my Gen 3 has an odd starting problem and before I tear into it or start lobbing parts at the problem, I wanted to see if anyone here had this issue or something like it. Often, when I start the engine, it takes 2-3 twists of the key from "acc" position to "start" position, before the engine actually turns over (recently more twist have been needed). It's actually been this way since I purchased it about 80 - 90k ago. Everything is normal, my battery is almost brand new, I have a fresh alternator, but this problem has been consistent throughout my 8 year ownership.

Here's my best description: When you insert the key (either my regular key or the spare) it goes in normally, move the key to the accessory position and everything comes to life (dash lights, alerts, heat/ac, etc.) as it should, then when you twist the key to the start position, nothing happens except a single "click". For the past 8 years, I would let the key return to the "acc" position, then twist it again, and the engine would start normally. That is to say, the starter is not labored, it doesn't take many battery turn-overs to start, it's almost instantly running when it engages. I've never really tried to repair or even diagnose the problem, because it has been very consistently starting on the 2-3rd twist without fail for years. Recently, it has increased to 4-5 twists, and yesterday it was 7-8.

SO, I guess it's time to actually track down the issue and resolve it before I get stuck someplace.

Per above, this problem has happened with an old battery and a new one, an old alternator and a new one. The starter, once engaged, has no trouble at all. I've tried starting in "P" and "N" and the problem is consistent, no mater which one I am in. If the Monty is in "P" it doesn't seem to care if the foot brake is depressed or not. Wiggling the wheel (which seems to help in situations that have a short in the steering column in some vehicles) seems to make no difference.

Anyway, I realize this is probably some tiny, hellish to find, relay someplace and I hate doing electrical. I was just wondering if anyone had experienced a similar problem or knew a good place to start looking.

Thanks for any help or advice you may be able to offer!

 

[Salonika]

I’d say the starter solenoid is sticking but not for 8 years......but it is getting worse so who knows. I’d start by cleaning all the starter electrical connections.

 

[DaveInDenver]

I assume Mitsubishi uses Denso starters as does, for example, Toyota, Dodge and probably many other makes.

If so, the majority of the time this happens it's the starter solenoid contacts and is a simple and cheap fix. You may or may not actually hear the solenoid clicking but the symptoms sound just like you describe.

You should make sure the battery, cables, ignition key and maybe any interlocks (like a parking safety switch) are OK. But in my experience with Toyotas it's always been the contacts for a flaky starter.

The difficulty is tearing into the engine bay and actually removing the starter to replace them. The contacts alone are a few dollars, you can get them at NAPA among other sources. The kit looks like this but you really only need the "L" shaped contacts most likely. The bolts, nuts and insulators are usually OK.




A complete rebuild of the solenoid (which is contacts plus a plunger and maybe a spring) is a bit more.



You'd have to do a little research to figure out what parts you actually need but, assuming it's a Nippondenso or Denso, it should be some variation of this.

 

[ajm291]

My 2006 Montero randomly does this too. Turn key forward (clockwise) to start, but nothing happens. Turn key backwards (counter-clockwise) like you're shutting off the car, and try again - then bam, it fires right up.

I haven't dug into this as a simple retry seems to work reliably for me (plus it's still miserably cold in PA so I have no motivation to wrench on my rig until the weather breaks)

 

[Skidmarkart]

Got a new solenoid. Going to to install and see if it helps. Will update after the work is complete.