Greetings, I am new to this site and to forums in general. Forgive me if this is posted in the wrong area. Anyway, I have a 2000 model year 24 valve diesel. Over 200,000 miles and very few problems. replaced the fuel system a few years back with the FASS. Now, or the last few months I have been blowing the 20 amp starter solenoid fuse. May need to replace it every start and sometimes it may last 10, 15 or 20 starts. Worse on cold days. Went through 5 fuses this morning and never did get it to turn over. Just a "click". I have been thinking I must have a short somewhere and I was going to replace the solenoid (on top of the starter) just for the heck of it. Then somebody told me they think it is the clutch interlock switch. Another site sent me a tech bulletin from chrysler stating this is a normal problem for the starter relay circuit and I should replace the relay harness and some other 25 amp fuse (fuse "D"). Anybody have experience with this, and if it was the starter relay harness why did the problem show up after 9 years and 200,000 miles?

 

Larry b's is a good website for the relay harness.

 

the contacts in the solenoid are worn out and the circuit is shorting to the case. you need a contact kit like the one larry b sells

 

OK, have it ordered and on its way. Thanks for the help.

 

had similar prob last winter. turned out to be the clutch interlock switch wiring shorting out, being pinched by the clutch pedal itself! I put some wireloom on the wires and rerouted away from the clutch linkage. hope this helps

 

Where was it being pinched. In the cab or under the cab?

 

in the cab, right where the clutch pedal arm comes close to the floor pan