Every once in a while for the last six months the fuse for the starter solenoid will blow when I try to start the truck. It's the mini 20 amp in the fuse center under the hood. If I simply replace the fuse, it'll blow again. If I go under the truck and jump the starter lead with a screwdriver it starts right up; then if I replace the fuse after doing that it will keep working fine for dozens of starts until one day....thar she blows! Anybody experience this? Do you think it's time to replace the starter? 164,000 miles on this one. And just as a note of interest I'm still on the original LP and VP.

 

I would install a new set of starter contacts. I imagine you'll find the one from the battery paper thin. http://www.fostertruck.com/dodge/default.htm

 

Thanks J, that's a good source for parts. I'm just wondering if maybe after 164,000 miles that the brushes are almost gone, too. I might be better off with a new starter(not reman). NAPA has one for $209. Any others out there have this experience?

 

Well I'm quite sure the starter hasn't got them miles on it. Highway miles don't really equate to a "well used" starter. Now if you had low miles and shut down/ started the truck 15 to 20 times a day that would more likely wear out a starter.

 

Start by looking at the contacts. (Actually, 1 contact takes most of the wear.) Contacts are cheap, easy & frequently the problem - but look 1st. Many mass rebuilds are junk. Installing rebuilt without 1st inspecting the current starter is simply throwing parts at a problem & is the expensive way to fix it. In this case, $200 vs $40.

 

Mine did this to me while I was at Home Depot. I jumped it off just like you discribed to get home. I went ahead and bought the contacts mentioned above to replace my old ones. When I removed my starter I found all the starter bolts loose and it was not getting a good ground. I went ahead and changed the contacts even though my old ones looked almost perfect. So long story short......Check your starter bolts for tightness.

 

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I had the same problem at 170K. Contacts wer good, solonoid was bad. Replaced with a rebuilt from O'Reilly's for under $200 and with a lifetime warranty. Now at 238K with no futher problems.

 

This thread has some good info; especially the TSP info. Very interesting I think that Dodge is aware of problems here.

https://www.dieseltruckresource.com/...d.php?t=126244