Every new starter will be smaller than the Bosch item, they have all gotten much smaller over the years. It will still crank faster than the old Bosch did.
Sounds like you just need a new starter. Best advice I can give you is to buy a new starter from a reputable brand, like Bosch.
I have two Tundras with 2UZs and a 4Runner with a 3UZ swap... None of them have ever needed a starter replacement... I could probably do that job in 45 minutes, which is better than owning any American vehicle.
This is exactly what happened to my 2004 corolla. Working all fine fresh battery alternator everything works had no issues. Next morning went to start it, nothing. I was thinking maybe electrical issue or fuse? All fuses and relays were good. Last resort I though could it be the starter? I’ve heard you can tap a starter with a hammer or wrench and if it attempts to start or actually starts, the starter gear is starting to wear out or issues with the starter solenoid. In my case, the starter teeth were all chewed up and it was crusty inside. Original starter after 168k miles. Fixed the problem. Been good ever since.
Just had exactly the same problem on my '09, needs a starter. Well more accurately the solenoid that pushes and pulls the starter teeth onto the flywheel is underperforming, and when cold it doesn't get off the flywheel fast enough to keep from barking the starter motor against the faster spinning flywheel.
I bought a Bosch Reman for about $260 with a 5 year warranty, went in with a moderate amount of persuasion. The oil filter, dipstick, oil pressure sensor have to come out to do it. You being from Chicago might have to fight to get the dipstick holder out without breaking it.
I used to have a Bosch starter. Rock solid even well below freezing. Solenoid broke. My current starter is whatever generic garbage they put in, and it doesn’t catch the first time I start it in sub-20F weather.
With a bit of searching, you can find more information about this starter swap. I would get the newer starter. There are so many benefits of the newer starter vs putting in the old and heavy starter that the factory used. Use SR0407X [Bosch number]/09A 911 023BX. You also can use the SR0424X/020 911 023FX but it's not as powerful. The SR0407X starter is for the diesel and has about 2hp to crank over your engine. This is way more power than you will ever need. That starter also is smaller and uses a planetary gear system so it will spin the engine at a faster RPM.
BOSCH SR4151X
i also noticed that the starter is the original bosch and the positive power lead going to it has some of the insulation cut off right where the wire bends to screw to the starter.
We got the battery tested - it's fine. Tried tapping the starter, but still no joy.
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