DIY: Repair a Denso starter solenoid from a Toyota

Toyota says it is a "non-serviceable" part. Once it's worn out, you have to replace it with a new one. Is it repairable? Let's find out.
This one is from a Corolla but almost all Toyota cars use this kind of solenoid.

[@william.2102]

I admire your ability to make repairs using creativity and craftsmanship. Nothing better than fixing something that the manufacturer says can't be fixed. NICE JOB!

[@queenslander954]

Brilliant repair mate , you’re a breath of fresh air for all blokes of the world that’s programmed to just replace every little thing.

[@c.meyers2882]

Thanks for all your videos - I like your style and ability to see potential in everything. My house is full of nice things that people threw away and I fixed, from computers to microwaves, stereos, toaster ovens, bicycles, washing machines, motorcycles, snowblowers, lawnmowers, power tools...everything. It kills me what is in our local dump - and now they won't let us take any parts. It's all "recycled" (i.e., destroyed).

[@TelloDaniel]

In México, you get a "10" when you do an excellent job. You've got "100"!

[@fred.nestler814]

AMAZING!! I GREW UP WITH A FATHER THAT COULD FIX MOST ANYTHING--LIKE YOU.I LEARNED A LOT BUT NOT ENOUGH. EVERYTIME YOU REPAIR SOMETHING NEW--YOUR KNOWLEDGE BASE INCREASES, SO FUTURE REPAIRS BECOME NOT AS FORMIDABLE. WHERE DO YOU "FIND THE TIME"? IT'S A DELIGHT ---WATCHING YOUR VIDEOS --FROM A MASTER OF MANY REALMS!

[@steveanocalli]

you are a thinker, brilliant, smart and very resourceful. thank you for sharing your knowledge and experience.

[@armandolopez8983]

I'm an old geezer and this video brought back great memories! GOOD JOB!

[@dgmenace73]

Great determination and very good video! It ain't broke until you cannot fix it anymore is something my grandfather used to tell me. When I was a kid my grandfather showed me how to drill out the rivets on a lawnmower solenoid, clean & grease the contacts, then put it back together with screws. I fixed a lot of them in my life and this is even a better example of fixing a "non-servicable" solenoid.

[@robertgilliland3273]

Very nice! Never considered repairing a starter myself. Thanks for taking the time to do this.

[@mJlReplicanT001]

I’d love to see this man gifted a nice new set of pliers . Legend, thank you, learnt and settled a huge case of curiosity that’s boggles the mind for some time now :) 🙏🏻

[@makantahi3731]

thank you on showing how it looks like inside

[@servihomestead4324]

Good work, sir. I also like to fix things as often as possible before throwing them in the trash or recycling pile. Thank you for encouraging me to save money and try this repair.

[@hopefilledsinner3911]

Your a legend in my eyes. I think you just saved me 300 $

[@maxg5457]

I basically done the same thing for my solenoid For skoda 94 Instead of flipping the copper contact plate I clean the contact area add a washer for compensating the worn copper it worked like new

[@lewisheilig3623]

I appreciated seeing the inside of your Denso solenoid because I am trying to diagnose why my starter failed the other day. If your Denso solenoid is similar to mine, which is for a 2004 Sienna, then there are 2 concentric coils inside your solenoid. One coil is called the PULL-IN coil. The other coil is called the HOLD-IN coil. Most ohm meters have a resistance in the meter's probe wires and you can determine that resistance by shorting the ends of the probes firmly together and noting the reading (mine was 0.4 ohms). Once you know the resistance of the probe wires, you can subtract that value from the resistance that you measure across each coil. Both coils connect to the same trigger terminal on the solenoid which goes to the key switch. The other end of the PULL-IN coil connects to the stud that receives the heavy braided copper wire from the starter motor. The other end of the HOLD-IN coil connects to the outer shell of the solenoid which is grounded to the engine. My PULL-IN coil measured about 0.4 ohms and my HOLD-IN coil measured about 0.9 ohms. If a bad electrical connection or a broken coil wire prevents the PULL-IN coil from passing current, then the current through the HOLD-IN coil alone will not allow the solenoid to do its two tasks, which is to switch battery current to the starter motor and push the pinion gear forward into the flywheel. After I cleaned up the outside of my solenoid, it is now working properly. I am left to conclude that my starter failed the other day because either the nut on the lower copper stud wasn't tight enough, or there was dirt between surfaces where electrical connections take place, or the miniature relay in the fuse box was not sending 12 volts to the trigger connector on the solenoid for some unknown reason. I hope this additional information helps.

[@haf-oq3vt]

You are very kind to show how to repair the car tool. I did something like this and in addition i welded a copper wire to the worn copper sides with tig welder machine.

[@DAT-TEXAS-DUDE]

Amazing job brother wish I had the patience and skills you do cause I would be fixing everything I could possibly fix by myself

[@jordanteets6252]

You sir, are a joy, and an inspiration. Thank you. You are amazing. Thank you for this.

[@jirojosephesman8175]

Great video...I'm grateful for your knowledge..sharing is your gift ..thank you have a blessed day and be blessed

[@michaelulett2828]

Thanks for teaching me this. Very valuable lesson. Continue your good work.

[@confranaprenderan9864]

This was great, thank you so much for showing us your skills and helping me...😊

[@owensdaniels6244]

wow! that was realy good sir you are awesome!! i wished you were in my family to teach us those things about cars

[@nandrth]

Very good Video and I’m about to fix mine today. Thanks

[@marianonoriel3397]

If Fucking Mc Guyver made a series in Vietnamese, you are that man!

[@sonnynguyen8012]

Great job buddy. Thank you for useful video.

[@NinoPrez007]

Absolutely brilliant my man!🇨🇦😉👍👍🎸🎸🍺🍺

[@MiteyMOofyearsAgo]

I'm impressed!, Thanks for sharing

[@Coolpool2002]

you sir are a true genius

[@marusvihldt2623]

Superb instructions, Thank you

[@KenyaSheriff]

That worked great! Thank you my friend.

[@hotpepper3604]

Good job sir.👍🏻

[@charlespaulfebruary4247]

Great Job in teaching me n bit of your Abilities 😊

[@dr-gaberibrahim5268]

Great video Good job

[@maxg5457]

You can compensate the worn by adding a thick washer or steel ball inside the weight where the spring is located You can get away with this without dissambling the solenoid

[@Surf_Salt]

Thanks! The world needs more people like you. prior to opening is there a way to determine if its the solenoid or the starter motor itself that's an issue?

[@tipsandtricks5258]

Brilliant. Saves me some cssh with this

[@twainjones]

Great job 👍👍

[@hobbyadventurer583]

Wow,I am impressed by your clear knowledge of that stater solenoid repair example.Is it possible to reach the solenoids 2 screws at the back to take that solenoid off the starter without removing the whole stater.Thnx

[@datrovertzchannel7287]

Amazing, thanks for sharing ❤

[@richardlove4287]

Subbed! Great info thank you.

[@bluzzpower]

Pure Genius!.. When in doubt Macgyver IT!👍

[@ThadeousMonkey]

Good information! Thank you!

[@aultraman]

Hey man, you are just amazing on repairing stuff. Did you know what kind of repair was required before you attempted to open the solenoid casing? Or you just opened it and came up with the solution as you troubleshot it? I look forward in seeing more of these uploads from you.

[@mobmob5944]

Probably just likes to save money and maybe has had this same solenoid with the same car, while also fixing other brands of solenoid’s that are essentially the same thing just made by a different . And im pretty sure he also learns or learned from watching other people make mistakes or make repairs on mistakes that anyone made. -the brain never stops learning-

[@user-gv1ws2cb3w]

Hi This is the best video ever made to fix the start motor !! I subscribe your chanel !! & wathing your all video~~

[@marcogarofalo6343]

Good job. Btw I love your accent.

[@kuttiprabhu786]

Superb....Superb....very very useful ....pal

[@Charlie9165]

Great video. Thank you. Do you know if this would also apply to a 1997 Toyota rav 4?. My starter keeps running after shutting off the engine. I think the solenoid may be stuck.

[@rob6067]

You are the king!

[@adrpals2324]

Good job.

[@haywardkong1213]

Interesting, I just replaced my 2014 Subaru Outback Starter and plan on rebuilding it later. It's interesting the solenoid can be repaired.

[@josephspellman2698]

Prob how "dEnSo DoEs iT", thanks for the info!

[@bparsons72007]

Good job but I believe the e-clip will last longer than the aluminum washer you installed as once it heats up it'll try to return to it's original shape.

[@jasminsmith9887]

You’re awesome! 👍

[@bobsoft]

How are you keeping the water out of the solenoid coil now that the seal is compromised? Saw a method that I tried today,. You use a nail and hammer to push the folded over part up and away. Then de solder the leads to the coil and remove the top part. After you sand or file the copper contacts smooth you can put the top back on and hammer the metal back in, solder the leads and seal the edge with silicone. It worked very well.

[@QuraishAlQurabi]

Good Job man👌🏽

[@efrainberrios8494]

Great!, thanks for posting this video and I send you a like too!

[@user-ut9ln4vd5m]

What year is your starter from? I thought the older 80s & 90s Toyota starters had a lot more easily replaceable parts, but don't recall exactly. Unless just replacing the whole little solenoid part is the idea?

[@marcus.H]

Did it stay reliable or did it break later?

[@richmadrid9563]

May I know what was the size of the thread tap and the screw you used?

[@Queteimp]

Exellent video. 100 pts

[@lucidslc269]

Hell yeah!

[@EJ3.16]

👍🏻👍🏻excellent thank you …

[@tedbullpit6164]

So it's been 2 years how did it hold up

[@baazigaj9125]

great video, I got stuck with assembly. everything is in the spec as shown but upon assembly the starter doesn't turn. any cheats

[@darrensmith9407]

Could you have soldered a blob of solder on the copper plate to make it thicker? Good vid 👍

[@doomsday9926]

What are the symptoms of a bad solenoid compared to a bad starter motor

[@georgehofgren6123]

Is this solenoid still working, or did it start not working again? 🤔

[@itslifegowithit8495]

Why not add solder to the worn down copper 😂

[@dayadam16]

Its hard to solder to copper champ. You normally remove the copper enamel just to solder to it

[@g.j.dutoit4447]

Why if bench test ford ranger starter, it not stay ingage if i keep small wire on pin. It uningage with start small wire on start point. It must only uningage only when i take of start thin wire, am i right or wrong? Rrrrrealy hope someone can help me. Thanks guys.

[@damianbutterworth2434]

When I worked at Valeo repairing solenoids we used to get new clips for the contact. Much the same as what you made. I used to repair about 150 a day. Bosch 0331 303 ---. We had presses and automatic de solderers. Pity they moved it all to France.

[@JBulsa]

Sell that homemade clip. Add List of tools needed for this repair in description.

[@BrianAndersonTT]

Wow.

[@raitshots]

😎👍

[@CastingSpell]

How do you know if whats bad is the starter is the solenoid?

[@donald8354]

Good question?

[@CastingSpell]

@@donald8354 not really, once is out, you conect it to the battery and you can see what's failing

[@bobsoft]

When the bendix gear does not come out or stay out (bouncing in/out) the solenoid is at fault. If the starter does not spin then it the motor.

[@JBulsa]

An improved design would be: a thinner case w/ groves and shorter screws. What else?

[@JBulsa]

Shape the copper plate smaller w/ a thin titanium coating or self healing amalgam to not wear out.

[@JBulsa]

Can I mail you a solenoid? I'd need every tool you used to rebuild this. 1998 Camry

[@chikararexzpo]

I am surprised you didn't grab one of those 24v semi truck starter and make a bike or some old motorcycle frame in the junkyard 🕳️👅🕳️

[@bownsweld]

The C clip would be better it is made of spring steel, it would never come off

[@10OZDuster]

dumb question is a solenoid really just a BIG relay ?

[@vuaeco]

In a way, they are basically the same. They are both relays. The only difference is in their functions. Relay functions as an electrical switch to relay small current to a different circuit with a bigger current. Solenoid does the same thing except that it also needs to move the pinion on the starter to engage with the flywheel. Not only is it an electrical switch, it is also a mechanical switch.

[@richmadrid9563]

@@vuaeco May I know what was the size of the thread tap and the screw you used?

[@fun_ghoul]

You'd be dumber if you never asked.

[@mongosmash100]

Great fudging video. 🎉👏🏻

[@billiebobbienorton2556]

Was NOT able to separate the solenoid. Tried as shown but screwing the screws in resulted in two bulges in the solenoid housing, it not separating and the housing becoming useless and not rebuildable.... Thanks for nothing.....

[@fun_ghoul]

You buggered it up, and now you're blaming someone else. Don't lie: Did you use an impact to screw in the screws?

[@TrehanCreekOutdoors]

There is nothing foolproof to a sufficiently talented fool. Just saying.

[@vuaeco]

Very well said!

[@generalawareness101]

Toyota hates you and your vids showing Toyota owners that they don't need to be fleeced, nor purchase a new car because they can't get the parts (or costs ungodly expense) for their otherwise perfectly working Toyota.

[@vuaeco]

Well put, mate.

[@generalawareness101]

@@vuaeco This is the sort of stuff I love because I come from the generation when you fixed things not just go purchase a new whatever to replace it. With the current world issues you would think more people would try and figure out how to keep old Bessie running than to just turn her into glue to then get into debt to buy a replacement. Just think that people like you in a real Zombie Apocalypse will be leading the life of luxury in comparison to the ones who just throw things away instead. It is akin to an old joke that it is time to buy a new car now because the ashtray is full.

[@vuaeco]

@@generalawareness101 I grew up after the war in a third world country so there was absolutely nothing around me. The only toy I had was the one I made it myself. I think in a way, it affects my way of thinking because even after living in a land of plenty, I still think it's wasteful to throw away what people think is "trash"! LOL (maybe that's why my wife complains I hoard too much trash!) My kid now has more toys than I would ever dream of in my dreams when I was a child. Most of his toys he only plays once and never to be seen again. What a stark difference there is in just one generation.

[@generalawareness101]

@@vuaeco I agree, and my life is very much in parallel to yours. I was kidnapped and spent the first five years of my life in countries that are still shitholes (still impoverished) 49+ years later. I really didn't start to see stuff until I was an adult. My family was so poor that the adults in my family would eat Bologna for dinner so my sister and I could have hamburger. We are all hoarders. I am not to their level, but I will horde screws, electronic parts, stuff like that so I don't have to purchase them again in the future. Seriously, look at the generations pre computer and things were built to last. Buy a piece of furniture today will it last 500 years to be passed down from family member to family member? Nope, and you know what is the saddest part about that? Most modern generations would say "I don't want that junk I want new." I have seen that, and I have heard that first hand. So sad. Don't worry the global depression is coming (when precisely I don't know, but it is coming) then the people will freak out while we know how to handle little and do much with it. Grasshopper and Ants comes to my mind.

[@fun_ghoul]

@@generalawareness101 Fellow "poverty brain" sufferer. Hi. 👋

[@SparklingRufus]

Solenoid should last forever.

[@Mattlawton-ft6ew]

No

[@timothyproksch2915]

I ca rumba

[@terrorriizz]

the reason for the malfunction doesnt make sense to me. nor does your repair idea. looks like the contacts just need some leveling, they look like they're just melted a bit from the electrical arcs. but even that doesnt make sense to me why its broken hehe thanks for tearing into this for us to take a look. toyota could have made this serviceable, too. the solenoid could also use a little better sealing where you cut to open it. at least some electric tape or "school glue" lol

[@vuaeco]

Believe it or not, this starter has gone through 200,000 miles. It doesn't look like it's worn much but you have to remember it has to run a very large current. Once it's worn down to a point it cannot support that amount of current any more, it will quit. Well, it is still sealed, there's no exposed part on the solenoid.

[@fun_ghoul]

Vu lives in SoCal, Noah. What's gonna happen...snow? LOL {checks news} Uhh...never mind. Eesh.

[@nenodyakov5901]

The new solenoid cost only 30 usd it's waste of time to repair old

[@HDHD-yv9np]

Not everyone have access to parts like you in USA.

[@jeremycanning8934]

Another stupid title. If it's unrepairable then it can't be repaired

[@zdzichzcan2808]

Thanks

[@DeeezNutttts]

You went through a lot of shit my man