This is actually the wife posting----this morning we had an interesting event. When the husband cranked the truck to leave for work, I noticed the truck didn't sound right and that he waited a little longer than usual to leave. Didn't think a lot about it until he returned a few minutes later. By the time I got to the door, the hood was up and within a few seconds a puff of smoke and some flames emerged. The truck died, then re-cranked itself. After fire was out and husband looked up, I asked what happened, and he said the starter relay got stuck(At least that is what I understood- I am a nurse, not a mechanic ). Anyway, a few wires got burned through and I don't know what else. Has anyone else had this to happen and how hard is it to fix? He just got the exhaust temperature gauge in and hasn't even got to see it work I know he is quite disappointed. Thanks for your input in advance> Have a nice day!

 

Not all that uncommon from what I've heard. The plunger sticks and burns up the contacts if I understood correctly. You can get a rebuild kit at the following site:
http://www.fostertruck.com/dodge/
Mishkaya

 

This event makes a good case for replacing your starter contacts before they act up.
Most likely the smoke and fire was the shutdown solenoid burning up, a $200 item. Might have took some wiring with it. The starter itself can be repaired for less than $20, don't let anyone talk you into a new one.
Anyone with 80k plus should replace their contacts before this happens to you.

 

just came from the rap.... dealer this part is now 500
then they nocked off 15% to help out
anyone figured out how to replace this with a manual shutoff
any other parts that was damaged please let me know

Moderator Please move this to the engine/drivetrain section

thanks to hearing about this happening on here at least I had a clue as to what was happening and was still at home when it happened

 

You can get a much better price on that solenoid at foster truck here is the link:

http://www.fostertruck.com/dodge/default.htm

You may need to replace some wires also. But so far, you need the starter contacts and plunger, and a new solenoid. May need some wire, and maybe a relay. You can always test the relay to see if it is still good. Probably is.

So now we are down to about $230 bucks, thats allot better than $500 . Kevin

 

You can replace the solenoid with a PTO cable for a manual fuel ON/OFF. Do a search on fuel shutoff solenoid, a few have done it and I remember one person who listed part numbers.

 

something to think about......as a starter rebuilder, I have seen countless stuck solenoids. If an engine runs even at idle for very long, the starter remains in mesh with the flywheel, and starter RPM limits are exceeded and the armature windings and commutator fly apart from centrifical force. Even if it doesn't SOUND like it exploded, take the back off the starter and look at the armature. If ANY commutator bars look lifted or winding string frayed, have it gone through. Gear reduction starters like ours are even worse, because the gear reduction acts as an overdrive when driven by the crank, sending starter RPM even higher than conventional direct drive starters.

And another thing.....these starters don't have to be expensive. There are dozens of applications that use our denso starters. They may change the drive, or drive end housing, but this is a $250 starter all day long. ANY rebuilder will have these laying around the shop from tractors, generators etc, and can use your drive end housing and gear to build one for less probably. If not, call Romaine Electric in Seattle, they have a smokin' deal on the medium frame Denso gear reduction starters.

my .02

Chris

 

I've got the parts comming ups from larryB's solenoid, contacts and plunger, and some brushes(I figured I'm gona have it off anyway may as well check and/or replace them too.) I've done a search for the manual shutoff using the choke cable but cant seem to find any post with part numbers. If anyone who has done this could please post some and some instructions and/or pictures I would be grateful. From reading the other posts it seems that the old solenoid housing and other parts may have been used. If it happes again this is the way I'll be going if I can get some good directions! Thanks again guys.

 

Dodge, I have a manual shutoff in my truck. I used a choke cable that you can get at any auto parts store, I'll try to get part numbers tommorrow( I happen to work at one ) and I reworked the linkages, I'll get some pictures.

 

Dodgecaveman use your search engine and go to the International truck site. It has dealers listed and a photo and part number for there PTO cable assembly. Nice heavy unit that should last forever.

 

Just did some checking, Advance Auto has a Worldwide rebuilt starter for $140 and AC Delco Rblt for $155. Part # 17003 on the Worldwide and 323546 on the AC. Lifetime warranties, so you'll only have to pay once Dodgecaveman I'll be at the shop today, I'll get those pictures of the linkages and post them tonight.

 

Ok I messed up. That's 1st gen stuff above. The 2nd Gen starter is $200 and its part # 17244. Worldwide is the only one they carry for that one though.

 

Thanks Smokinfive9 right now I'm hopeing that it is still ok. When it finally burnt the wire to the solenoid the fuel had already shut off and the starter was still running trying to recrank it. It probably turned over the engine three or four times (maybe more I really wasnt counting was just ticked because I had just wired up the box for the EGT probe the night before and was looking forward to actually seeing what my temps were going to be) before it stopped.

 

Didn't make it to the the truck today to get pics, but tommorrow for sure! Sorry for the delay.

Hope it is ok, but I'll get the pics for you just in case, and I've been meaning to get them anyways in case anyone else needed them. This gives me a reason lol.

Hope all is well, don't let it get you down, our trucks just like to let us know who's in charge one in awhile