1999 4WD, 120K miles

Just replaced the starter motor for the second time

First time, symptom was click,click, no crank. Common symptom

Second time, the motor was slow to crank, and got worse over the course of a week, acting like weak batteries.

Replaced the starter, and vrooom, starts right up.

Word to the wise, check the batteries, but look at the starter as a culprit also.

Mike
Tucson

 

the first time you replaced it. it sounds like a new set of contacts would have cured it, contacts range from 5$ to 30$, my truck has 437,000kms on the same starter, and I have replaced the contacts once.

 

how many start cycles ???

 

You couldve just replaced starter contacts, much cheaper

 

Kinda funny actually, I'm the 3rd owner, previous 2 were from the same family, when I got the truck in May 07 it had 297,000kms, now it has 437,000kms and I use the truck for intown courior work, it sees 8-10hrs daily (700hrs of run time since Jan) I do 40-60 pick-ups/drop offs every day and 99% of the time I have to shut the truck off once I'm backed up to a dock. so it sees lots of starts. I cant say how many starts the previous owners did, but I bet I've surpassed 'em
If you ever need a product tested I'm your tester!! I bet I rack up more miles in a day than most folks rack up in a week.
I spent more in fuel last yr than I paid for my truck! 15,000$ in fuel and the truck only cost 14,000$, the previous yr I spent 11,000 in fuel

 

Put a scan tool on the truck and it should tell you how many starts the ECM has made.

 

My dually had this problem too, just about replaced all teh cables in the truck. Replaced both batteries because of it. Took the starter apart, one set of brushes were wore down to nothing, and had some serious arc pits on the slip rings.

 

I have a similar problem. It doesn't happen all the time just on occasion. when I go to start it it will just click then it will start right up. How do you replace the starter contacts?

 

,If its clicking occasionally its only a matter of time before it quits all together. here is the instal instructions

http://www.fostertruck.com/contacts_install.htm

http://www.fostertruck.com/dodge/starter%20faq.htm

and for parts
http://www.fostertruck.com/dodge/default.htm

I purchased the contacts only from a local alt/starter rebuild shop, paid like 6$ for the pair of them, shortly after I ordered the kit from Fosters truck, that set is sitting on the bench, one day when I'm bored I'll replace the stock ones with the upgraded contacts.

Dont forget to check all the other stuff first, battery connections/battery condition(load test) and cabling. even after pulling the starter and rear cover, its pretty obvious if contacts are required or not, heck for the cost and piece of mind replace them any way.

** note when tightening up the contact stud make sure that the contact does not flip up, and that it remains square to the back of the case, if it "lifts" it wont allow the plunger to contact evenly, thus wearing out the new contacts pre-maturely. I snug the bolt then use a screwdriver/punch and hammer with a light tap pushing the contacts down. then finish tightening up the stud, usually this stop the contacts from shifting. hard to explain but easy to spot when you are installing them, if you know what to look for.**

 

Or they will stick and keep cranking. This happened to my 12v a week ago, not a fun way to start the morning. Luckily I had a spare starter in the garage. Time to order some contacts so I have a good starter as back up.

 

too true!! bad contacts can cause quite the issues from slow cranking to stuck on, I think the starter contacts in a 12V cause issues with the fuel shut off as well, think I read that on the foster site as well, they have some kind of resistor or something for it.

 

The older ones had that issue. My 98 didn't, turned the key off and the engine shut off, but kept cranking. I'd really like the wiring schematics for a 98 to see how it is wired. With the 94 wiring, it would cause the pull circuit in the solenoid to stay energized and burn it up.

 

Thanks for the info Nick. pulled the starter yesterday and sure enough 1 contact was wore paper thin the other looked like "new". Have to wait until Monday to call a couple local shops for the new contacts though. everything else checked out OK and I'll probably order the upgraded kit for the next time.

 

Something else to consider when overhauling the solenoid. Change the spring that makes the plunger return. A weak or collapsed spring will allow the starter to stay engaged after the engine starts.
I had the click, click, click thing going on, then the engine would start, but the starter stayed engaged. = collapsed spring was the culprit. My starter person told me that it collapsed due to the heat buildup from the contacts going bad and trying to draw a lot of amps. I let my starter person change everything and only cost me $39. (BTW, I did remove the starter before taking it to him)

 

one other thing to watch out for. I pulled the starter motor off to gain access to the solenoid cover but when I did I pulled the cover off the armature! what a PITA! Those 2 little phillips head screws are rusted on! Luckily the starter guy put everything back together with new contacts and new screws on the starter motor cover for only $10. He even tested it.