Mike Gerber

http://www.toyotanation.com/forum/showthread.php?t=124410

First of all, there is an easy test to determine if it actually is the starter contacts. The next time it fails to start, have someone hold the key in the start position while you hit the starter solenoid with a rubber mallet or a small hammer. Don't break it, just tap it a bit. If it's the contacts, this slight jarring should make the starter engage and crank over the engine.

I just replaced the starter on my 98 4 cylinder 5SFE engine a few months ago. Should be exactly the same as your's. Mine had 90,000 miles on it. It's really not too hard. Should take you about 30-45 minutes to remove it the first time you do it. Remove the battery, the battery tray and the bracket holding the cruise control on (3 bolts if I remember correctly) so you can move the cruise control out of the way. Some people like to remove the air cleaner box to give them a bit more room, but I was able to do it without removing that.

Then remove the 2 modular electrical connectors and the nut under the rubber boot holding the lead from the battery. Sometimes this boot and nut is on the front side of the starter and some times it is on the backside. It just depends on whether the car was delivered in what Toyota considers a cold weather climate. The cold weather climate cars have the boot and nut on the back side. Then there are 2 long 14MM head bolts that hold the actual starter in. The front one can be removed with just a wrench but you will need a socket and about a 4-6 inch extension to reach the back one. One this is all removed, just snake the starter out of there. You can then remove the solenoid for replacement of the brushes.

At 90,000 miles I opted to just have my whole starter professionally rebuilt. If you can find a reputable auto electrical rebuilder in your area I think this is the best way to go. IMHO, you get a better rebuild done when compared to getting an off the shelf rebuilt unit from most auto parts stores. Cost is about the same. It ran me $125. At 40,000 miles however, you may just want to replace your solenoid contacts. It's really your choice.