Almost every time I go to start my truck, the 20amp fuse for the starter solenoid blows. It may work fine for 4-5 starts then it will blow 2-3 times. It has gotten to the point where I will put a paper clip in, start it and pull the clip. I know this is not safe, but when you're late for work...
It is not shorted to ground, it acts more like a power surge when I turn the key to the start position. I don't know where to look further.
Ideas?

 

I would start by replacing the starter contacts.
Order and much info here http://www.fostertruck.com/dodge/default.htm

 

There is a TSB for that! Here.........
NO: 08-01-00 Rev. A
SUBJECT: No Start (Engine Will Not Crank) Due To A Blown Starter Relay Circuit Fuse
DATE: June 30, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-01-00, DATED JAN. 21, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.

OVERVIEW:
This bulletin involves installing a starter solenoid jumper relay/harness assembly and a new fuse.

NOTE: THIS BULLETIN APPLIES TO RAM TRUCKS AND RAM VANS/WAGONS BUILT BEFORE THE FOLLOWING DATES:


RAM VANS/WAGONS
• PILLETTE ROAD ASSEMBLY PLANT - ALL EXCEPT CNG VEHICLES - JANUARY 18, 2000 (MDH 0118XX). CNG VEHICLES - JANUARY 25, 2000 (MDH 0125XX).


RAM TRUCKS
• ST. .LOUIS ASSEMBLY PLANT (11TH VIN POSITION = "J") - JANUARY 25, 2000 (MDH 0125XX)
• WARREN TRUCK ASSEMBLY PLANT (11TH VIN POSITION = "S") - FEBRUARY 2, 2000 (MDH 0202XX).
• SALTILLO TRUCK ASSEMBLY PLANT (11TH VIN POSITION = "G") - FEBRUARY 7, 2000 (MDH 0207XX).
• LAGO ALBERTO ASSEMBLY PLANT (11TH VIN POSITION = "M") - FEBRUARY 14, 2000 (MDH 0214XX).



SYMPTOM/CONDITION:

The vehicle will not start (engine will not crank) due to a blown starter relay circuit fuse.

DIAGNOSIS:
Inspect for a blown starter relay circuit fuse. The starter relay circuit fuse is located in the fuse block on Ram Van/Wagons and is fuse number 17. On Ram Trucks, the starter relay fuse is located in the Power Distribution Center (PDC) and is fuse "D." If the fuse is blown, inspect the starter relay circuit forany electrical shorts to ground. Refer to the appropriate Service Manual, Group 8W-21 "Starting System Wiring Diagrams" for circuit identification, components, and their locations. If there are no apparent electrical shorts to ground in the starter relay circuit, perform the Repair Procedure.

PARTS REQUIRED:
Qty Part No. Description
1 04687835 Fuse, 25-Amp
AR (1) 05019014AA Relay/Harness Assembly, Starter Solenoid Jumper, Ram Van/Wagon
AR (1) 05019015AA Relay/Harness Assembly, Starter Solenoid Jumper, Ram Truck


REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.



RAM TRUCK

Disconnect the battery negative cable. On vehicles equipped with a diesel engine, disconnect both battery negative cables.
On vehicles equipped with a gas engine, remove the battery negative cable clamp-attaching nut and existing ground eyelet. Install the ground eyelet (black wire with eyelet) from starter solenoid jumper relay/harness assembly p/n 05019015AA onto the battery negative bolt. The ground eyelet should be placed between the existing ground eyelet and the battery negative clamp. Install the battery negative clamp nut. Secure the nut finger tight only at this time. On vehicles equipped with a diesel engine, remove the battery negative cable clamp-attaching nut from the left battery. Slide the ground eyelet (black wire with eyelet) from starter solenoid jumper relay/harness assembly p/n 05019015AA onto the battery negative bolt and reinstall the nut. Secure the nut finger tight only at this time.
NOTE: DO NOT CONNECT THE BATTERY NEGATIVE CABLE TO THE BATTERY AT THIS TIME.

If equipped, slide the insulated cover of the battery positive clamp down away from the clamp approximately one inch.
Remove the battery positive clamp nut (left side only on diesel engines).
If equipped, slide the B+ wire and eyelet (red wire with eyelet) from starter solenoid jumper relay/harness assembly through the battery positive clamp insulated cover.
On vehicles equipped with gas engines, attach the B+ wire and eyelet (red wire with eyelet) from starter solenoid jumper relay/harness assembly onto the battery positive clamp bolt. On vehicles equipped with diesel engines, remove the battery positive bolt from the left battery positive clamp. Slide the B+ wire and eyelet (red wire with eyelet) from starter solenoid jumper relay/harness assembly onto the battery positive clamp bolt. Install the bolt/B+ eyelet assembly onto the battery positive clamp. Reattach the right battery positive lead onto the clamp.
Install the battery positive nut. On vehicles equipped with gas engines, tighten the nut to 7.9 N• m (70 in. lbs.). On vehicles equipped with diesel engines, position the B+ wire eyelet so that the wire is pointing to the left (pointing towards the left fender). Tighten the nut to 9 N• m (80 in. lbs.).
Disconnect the gray connector (T40 14BR circuit) located on the right side of the power distribution center.
Connect the two remaining leads of the starter solenoid jumper relay/harness assembly to the disconnected gray connector.
Secure the starter solenoid jumper relay/harness assembly to the battery positive cable as shown in Figure 1. Secure the top of the relay by placing a tie-strap through the hole of the relay bracket and wrap the tie-strap around the battery positive cable. Secure the middle of the relay by placing at least four wraps of electrical tape around the relay and the battery positive cable. Secure the wiring harness of the relay assembly by placing at least two wraps of electrical tape around the harness and battery positive cable.
Remove the blown fuse from the power distribution center and install a 25-amp fuse p/n 04687835.
Connect the battery negative cable(s). On vehicles equipped with gas engines, tighten the nut to 7.9 N• m (70 in. lbs.). On vehicles equipped with diesel engines, position the ground eyelet so that the wire is pointing to the left (pointing towards the left fender). Tighten the nut to 9 N• m (80 in. lbs.). Reset the clock.
Verify the repair by ensuring that the engine starter circuit operates.
NOTE: A SUPPLEMENTAL WIRE SCHEMATIC FOR PAGE 8W-21-2 OF THE 2000 RAM TRUCK SERVICE MANUAL (PUBLICATION NO. 81-370-0008) IS ATTACHED TO THIS TECHNICAL SERVICE BULLETIN FOR YOUR REFERENCE.

RAM VAN/WAGON
Disconnect the battery negative cable.
Remove the battery negative cable clamp attaching nut and bolt. Slide the ground eyelet (black wire with eyelet) from starter solenoid jumper relay/harness assembly p/n 05019014AA onto the battery negative bolt. Install the battery negative bolt/ground eyelet assembly onto the battery negative clamp.
Install the battery negative clamp nut. Secure the nut finger tight only at this time.
NOTE: DO NOT CONNECT THE BATTERY NEGATIVE CABLE TO THE BATTERY AT THIS TIME.

Remove the battery positive clamp nut.
Attach the B+ wire eyelet (red/gray wire with eyelet) from starter solenoid jumper relay/harness assembly onto the battery positive clamp bolt. Place the B+ wire eyelet between the existing eyelet (if equipped) and the battery positive clamp.
Install the battery positive nut. Tighten the nut to 7.9 N• m (70 in. lbs.).
Disconnect the gray connector (T40 14BR circuit) located to the right of the battery above the power distribution center.
Connect the two remaining leads of the starter solenoid jumper relay/harness assembly to the disconnected gray connector.
Secure the starter solenoid jumper relay/harness assembly to the headlamp and dash harness as shown in Figure 2. Secure the top of the relay by placing a tie-strap through the hole of the relay bracket and wrap the tie-strap around the headlamp and dash harness. Secure the middle of the relay by placing at least four wraps of electrical tape around the relay and the headlamp and dash harness. Secure the wiring harness of the relay assembly by placing at least two wraps of electrical tape around the jumper harness and headlamp and dash harness.
Remove the blown fuse from the fuse block (cavity 17) and install a 25-amp fuse p/n 04687835.
Connect the battery negative cable. Tighten the nut to 7.9 N• m (70 in. lbs.). Reset the clock.
Verify the repair by ensuring that the engine starter circuit operates.
NOTE: A SUPPLEMENTAL WIRE SCHEMATIC FOR PAGE 8W-21-2 OF THE 2000 RAM VAN SERVICE MANUAL (PUBLICATION NO. 81-370-0007) IS ATTACHED TO THIS TECHNICAL SERVICE BULLETIN FOR YOUR REFERENCE.

POLICY:
Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Op. No. Time
08-90-65-97 0.4 Hrs.


FAILURE CODE:
Code Description
P8 New Part

 

Check the solenoid contacts. I considered the TSB on mine but figured the truck was old enough that the problem would have shown up earlier than 110,000 mi. Contacts needed replacing.