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.]

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!

[steveanocalli]

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

[queenslander]

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.meyers]

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.nestler]

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!

[dgmenace]

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.

[armandolopez]

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

[maxg]

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

[lewisheilig]

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.

[robertgilliland]

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

[Hamid-az]

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.

[servihomestead]

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.

[mJlReplicanT]

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 :)

🙏🏻

[makantahi]

thank you on showing how it looks like inside

[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

[doinikinsv]

Much better if you put epoxy on the opened crimped area so that dirt and water won't go inside. Great DIY repair!

[jirojosephesman]

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

[hopefilledsinner]

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

[marianonoriel]

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