Preventive rebuilding

[Prairie Dog]

So my truck has turned over 104K. It's been a great truck - super reliable and i want to keep it that way.
Not only has my truck had to make lots of short trips of 4~7 miles, we also use it for frequent camping trips. Above all else, I dont want to have issues while on the road.
In your opinion, does it make sense to replace the starter contacts/solenoid and install one of the alt. rebuild kits at this point or should I expect a lot more miles before any troubles?

Thanks,
Scott

 

[lpennock]

I would expect more miles.

 

[BLNRAY]

my 03 turned over 427k on the way home from work last nite,original starter never been off the truck,removed alt at 420k to rebuild,was worn out to the point it was not rebuildable but still working.if it ain't broke dont fix it.

 

[Wayne M.]

Agree. Not touching mine. 125k 4500 hr short haul miles.

 

[petersonj]

does it make sense to replace the starter contacts/solenoid and install one of the alt. rebuild kits at this point or should I expect a lot more miles before any troubles?

When I had 130,000 miles on my truck I spoke to a representative from an auto-electric shop with lots of experience with these trucks. I asked him if for a quote on a rebuild kit for a Bosch alternator. He asked for how many miles were on the truck. When I told him, he said that he would be happy to sell me the brush and bearing kit, but that I was only at half life on the brushes, and at one-third life on the bearings. I waited until I had 215,000 miles on the truck and then changed them out - they were still in good operating condition.

As for starter contacts, I replaced them at 143,000 miles because of an intermittent cranking problem.

You could buy both kits (they are not expensive), keep them in your truck and install them when you think it is necessary.

- John

 

[Bob4x4]

Just do it........$30 an hour of your time

 

[phantomusa]

I ran my 5.9 1995 3500 over 700000 miles before I had any starter problems and I did change my alt at 675000 miles but it was my screwup it was still good I didn't catch a battery going bad

 

[petersonj]

I ran my 5.9 1995 3500 over 700000 miles before I had any starter problems and I did change my alt at 675000 miles...

I would have went back to Dodge and asked for a pro-rated warranty.

- John

 

[Prairie Dog]

Thanks for your input everyone.
I went ahead and bought the bigger contacts and new plunger for the starter. I've made so many short trip that I'm leery of it. I'll install them on a day when I have nothing else to do.
Also, I'll hold off on the alt for a while because of the comments you've all made. Seems like the bearings usually go first anyway and they give you plenty of warning.

Scott

 

[Motorhead]

Scott, My 2001, second gen, the starter contacts were shot at 65,000 miles. Thar seemed short life in my book. I did a whole bunch of work on my neighbors 1992 first gen and pulled the original starter with 235,000 miles on it. The starter contacts were barely worn... Go figure? One suggestion on installation of the contacts. When I am tightening down the anchoring studs that hold the contacts in place, I make sure the contacts are dead flat against the inside of the solenoid. This insures that the contact disc seats squarely against the contacts when the starter is engaged. Make sure there is no grease on the contacts too.

 

[Prairie Dog]

Scott, My 2001, second gen, the starter contacts were shot at 65,000 miles. Thar seemed short life in my book. I did a whole bunch of work on my neighbors 1992 first gen and pulled the original starter with 235,000 miles on it. The starter contacts were barely worn... Go figure? One suggestion on installation of the contacts. When I am tightening down the anchoring studs that hold the contacts in place, I make sure the contacts are dead flat against the inside of the solenoid. This insures that the contact disc seats squarely against the contacts when the starter is engaged. Make sure there is no grease on the contacts too.

Thanks for the tips MH. This is my first time doing the job so that's all very helpful.

 

[Motorhead]

PD, It sounds like you are keeping your truck for the long run. It can't hurt to pull the back cap on the solenoid and check the contacts. This can be done with the starter still installed if you so choose. One CAUTION... On the center contact PLUNGER there is a spring and at the end of the spring is a small ball bearing about 5-6mm in diameter. If you pull just the cap off in frame or if you completely remove the starter and disassemble it, be careful not to lose the little ball. It drops into a bore BEFORE the spring and center contact plunger does. I have rebuilt several of the various generations starters. It never hurts to remove them, clean the insides, inspect and lightly lube the bushings with a thin coat of moly grease. At least then, you know what you have from a dependability stand point. Last thing I want is for a component to crap out while on a trip. I have never tried to push start my stick shift truck!

 

[Prairie Dog]

All good stuff and thanks for the warning MH, I would have lost the ball in my gravel for sure.

Scott

 

[Motorhead]

I would have lost the ball in my gravel for sure.

Been there....Done that! If you wanted to check the contacts in-frame then have the REAR of the truck much lower that the front. I found the ball when it came out and was able to put it back in. Just pull the plunger contact out slow and try to keep the plunger spring in the hole in the center of the starter solenoid body.