Went to start the truck today (v-v-very c-c-c-cold) and all I got was a clicking sound when I turned the key to the start position. I tried the start position many times (20) and one time the starter cranked and she fired right up. The batteries are OK, not great, but they seemed to crank over OK once the starter kicked in.

Is this the problem you get with the bad starter contacts I have read about here?

Where are these contacts? Are they in the starter itself or on the starter solenoid that I think is mounted on the drivers side fender?

Could this just be from the cold - maybe brushes sticking in the starter? I had that happen on my old Thunderbird.

Thanks for the help!

 

Yep, sounds like your contacts.... they wear out very gradually and will eventually leave you stranded. Very easy replacement/fix. When you replace your contacts you will see that one of the contacts is worn considerably more than the other, (almost wafer thin). Your truck is a 95, so youv'e actually done quite well with the life of the OEM contacts.

 

Sidewinder,

The exact same thing happened to me. It began acting up as you describe, and gradually got worse. Fix it before it leaves you stranded. Noone warned me about the contacts, and I found out about them by pulling the starter and disassembling it.

It is very easy to do. Get the superduty contacts from fostertruck.com

I got mine from a local starter/alternator rebuild shop for $5. I replaced the contacts only though because at the time I didnt know LarryB had a rebuild kit.


Do the rebuild ASAP. Unless you wanna get stranded.

Just My .02
Good Luck
Phillip

 

It very well could be your batteries are near the end of their life, get them checked. As it gets colder the amperage output is reduced. By repeatedly trying to start it the load will warm the battery which increases the amperage, then it will start.
Replacing the contacts is cheap/easy and should be done anyway but if the batteries are the problem you still may get a no start plus the low voltage will wear out your new contacts faster.
Good source for contacts and instructions here-
http://www.fostertruck.com/dodge/

 

OK

I waited too long. Starter stuck on today. I had to do an emergency cable-ectomy to disconnect the batteries. I guess the starter is coming out tomorrow.

It's really cold here, how exactly does the starter come out. I looked at it today and was wondering how many bolts and wires need to be disconnected. Also is it easier to disconnect and remove it from the top or from under the truck?

I am trying to make the removal as fast as possible, like I said it's cold.

 

Not real sure on your 95, but on my 98 it takes a 10mm, couple of different extensions, and just a few minutes to drop the starter. Don't remember the size for the cables. Very easy. While you are in the solenoid, replace the plunger also.

Ed

 

Your 10mm socket has to be a 12 point. The 3 bolts are usually pretty tight. I've used a 10mm box-end wrench with a snipe on it. That's what lifetime guaranteed tools are for.

 

Those 10mm bolts can be a bear. Bent a wrench getting them off. Disconnect your batteries. I think the cable nut on the starter is around 3/4. It's a simple job, just takes a little patience and time.

Loren

 

Got it out.

Not too bad and the bolts were not overly tight. I guess this thing is metric? All of the best fitting wrenches were 8mm, 10mm and 15mm.

Opened it up and one of the contacts inside the solenoid is about the thickness of a peice of paper. The other one looks almost new. I guess the reason the solenoid sticks is that the plunger would have to twist slightly to make contact with both terminals because of the different thickness and then it would get stuck.

Anyway thanks for the help and Larry B here I come.

I do have another question now but I think I'll start a new post. I found a loose vacuum line and do not know where it goes.

 

I couldn't wait to order new contacts so I made some new ones in our machine shop. Bent some 0.125" copper bar and drilled a hole.

What a difference I thought my batteries were shot even though they are less than a year old. Was I wrong. With the new contects in it cranks better than when the batteries were brand new and now no more click, click, click... when starting and hopefully no more stuck starter!!

 

same thing happened to mine on saturday, click and no start, went to rebuilders today and got new contacts for starter solinoid, installed today and every thing good...