So this happened to me today too. HDJ80 with 217k.
Went to fill up the washer reservoir at Halfords, spilt a little bit around as you do. (mentioning this as ih8mud user had issue with wiring under the reservoir causing starter cutout...
No Start on a HDJ81, I have traced it down to a pretty small area. - [Leaving Land Cruiser Club])
Started the truck in the car-park, sounded a bit rattly but nothing to make me stop and look, as the engine was otherwise cold having only done a few miles. Drove the returning two miles home, went to kill the ignition and it would immediately try to crank and would start the truck when the key allowed it. Flicked it on / off about 10 times to see if this would 'unstick' - it did not.
Starter was smoking a little at this point, probably was 'starting' for about 5 mins by now. I had left the the engine running in the hope that this took the strain off the starter. I ended up pulling both -ve on the batteries, having discovered that there is no fuse that could be pulled instead. Truck continued to run without both -ves but totally died when the ignition was shut off this time, and when I hooked it all back up the problem went away i.e. the starter didn't immediately start trying to crank, and normal service resumed. I can't repeat the problem to troubleshoot it so far.
My thoughts
- if the starter solenoid had 'welded' itself to the on position, as I have read about, then reattaching the batteries would have resumed the starter trying to turn the engine over... no?
- if washer fluid spill has somehow upset the 12/24v switchover relay then that still wouldn't be sending a 'start' signal to the starter
- the starter relay could have been stuck sending 12v through
- I suppose the barrel wiring may be at play
- the spilling of washer fluid around this area is probably coincidence
I've read a bit on this tonight and have ordered the RoughTrax rebuild kit
Genuine Toyota Starter Solenoid Repair Kit - [Leaving Land Cruiser Club]
If the solenoid was stuck 'on' then killing the electromagnet by pulling the battery would not have unstuck it as the electromagnet would have otherwise been off already if this was the issue. And so reconnecting it would immediately make it 'on' again, which did not happen. It feels like removing the electric would have only made a difference to the state of the starter relay. Wisdom of the forum please!
This is what the inside of the starter solenoid looked like. Worn but not terribly so?
I will replace the starter relay too, but am struggling to source one - any ideas? 28300-17020