50 amp diesel start fuse burnt

[BillBaker]

My 50 amp diesel start fuse burnt out about 6-7 weeks ago. Replaced it and all was good and today it blew again. Noticed the past few days at times when starting the truck that it seemed to crank longer then normal. I'm reading a lot of articles that say it's the starter contacts going out. Has a cheap replacement starter in it that had to get replaced quickly at the time and I'm currently searching out an affordable OEM denso that I can swap in it with the big contacts kit. Wiring looks fine as far as I can see. My issue/struggle when it comes to electrical issues and diagnosing is I'm color blind and wires aren't so easy to identify. Anyone have any input to push me in the right direction? Thanks!

 

[Wayne M.]

Wow Bill, it happened again?
Refresh the memory, was the shutdown solenoid itself replaced?
Inferior aftermarket parts do often cause issues, and your thinking about the starter motor is valid, but I’m not sure if it’ll blow that fuse- I’d need to check a wiring diagram on that, but yes it is better to have a OEM starter with a contact kit.
Hopefully some 12 valve guys will fill you in ASAP!

 

[BillBaker]

Wow Bill, it happened again?
Refresh the memory, was the shutdown solenoid itself replaced?
Inferior aftermarket parts do often cause issues, and your thinking about the starter motor is valid, but I’m not sure if it’ll blow that fuse- I’d need to check a wiring diagram on that, but yes it is better to have a OEM starter with a contact kit.
Hopefully some 12 valve guys will fill you in ASAP!

Not sure if it's the original shutoff solenoid or not. I messaged the previous owner and am waiting response if he ever replaced it while he had it. I did take note the top of it has some cracks in it whether that's an indication of anything other then old age. If anyone's got a starter up for sale I am looking for one. Was going to a reman for a decent price but now they are on backorder and unavailable and the high priced new ones available are out of budget at this time.

 

[Timd32]

Two years ago I got a starter from my local cummins dealer for about $250, has a Chrysler plate on it is a very nice unit. Beats the $400+ ones online all day long. Not a cheap unit really really nice.

My positive cable was so degraded from my oil pan and PS/vacuum pump leaking on it all that was junk. You could have a bad cable, don't mess with the repairs of the ends and stuff, sounds like you have been down this road enough. This is a easy straight forward fix.

I recomend a decent cummins starter and a set of battery cables from Geno's.

If you get into a really bad spot let me know and I can get a new price on that. I'm not a dealer or parts place you can cold call the counter and explain you need a starter, private vehicle, in a bind.... for $35-$45 they can overnight it.

Have you registered your ESN on quick serve do you have the part number for your engine, not that it matters much they will update the number to the most current version.

IMO you won't beat the Genos battery cables they are a buy out product and the info is in their flyer.

Do you have a decent "set" of batteries. Make sure your set is matched and fresh or pick up some new ones. You can usually get some good deals on a set of AGM batteries from numerous big box retailers.

Batteries, starter, cables, done. There might be one more small wire in the starter harness.

And the good news is your starter 12pt 10mm bolts are already broken free, mine were super tight what a PITA to keep messing with the starter, cables, contacts, I also put new bolts in mine.

 

[GAmes]

The '98 must be wired quite differently than a '97. I don't have a start fuse of any amperage, just a relay.

 

[BillBaker]

... it'll be this weekend until I can dig into this. Batteries are new as of last year Timd32. Shutoff solenoid is original found out.

 

[Timd32]

3604684nw was the part I got, says 94-02.

Was brand new from Cummins distribution center has a red metal Chrysler tag on it.

Was $280.46, but I see them cheaper on some sites. Beware of knock off's....

Very nice starter.

If you call your local Cummins dealer/parts place they can use your ESN and make sure. But that was the updated PN back in May of 2016.

Batteries sound like they are good to go.

 

[BillBaker]

3604684nw was the part I got, says 94-02.

Was brand new from Cummins distribution center has a red metal Chrysler tag on it.

Was $280.46, but I see them cheaper on some sites. Beware of knock off's....

Very nice starter.

If you call your local Cummins dealer/parts place they can use your ESN and make sure. But that was the updated PN back in May of 2016.

Batteries sound like they are good to go.

Ok thanks I'll check on that starter. It's got a Chrysler tag on it you say?... I got the Larryb's contacts on hand hoping to find a Denso to swap them into but...

 

[GAmes]

I bought a new Denso several years ago. It came with a (one) oversize contact, the one that always burns out first.

 

[Timd32]

I found a quick reference guide on DENSO's site

You can try car-part.com and maybe there is a salvage yard with one.

94-02 Dodge 5.9 ISB
New: 228000-2292
Rebuilt: 9722809-229

Walmart.com actually has them listed for $252.00

https://www.walmart.com/ip/OEM-STAR...5-9-DIESEL-DENSO-NEW-OE-228000-2292/454370849

Is it real......... says it is.......

 

[Timd32]

Here is that guide.

 

[BillBaker]

I found a quick reference guide on DENSO's site

You can try car-part.com and maybe there is a salvage yard with one.

94-02 Dodge 5.9 ISB
New: 228000-2292
Rebuilt: 9722809-229

Walmart.com actually has them listed for $252.00

https://www.walmart.com/ip/OEM-STAR...5-9-DIESEL-DENSO-NEW-OE-228000-2292/454370849

Is it real......... says it is.......

That Wallymart is something. I got my Nitto terra grapplers from them for $750. The tire center wanted $1,000....

 

[BillBaker]

I bought a new Denso several years ago. It came with a (one) oversize contact, the one that always burns out first.

Why just one any idea?... can you share from where it came from?

 

[BigPapa]

The current Cummins part number is 3935888.

-Scott

 

[GAmes]

Why just one any idea?... can you share from where it came from?

If you have ever replaced the contacts in one you will see that one burns up while the other is barely worn. Apparently they know that. I bought it from a truck supply place that realized later that there is a high profit margin and raised their prices accordingly. I've deleted their site from my favorites. If I needed one I'd jump on the one listed at WM.

 

[BillBaker]

If you have ever replaced the contacts in one you will see that one burns up while the other is barely worn. Apparently they know that. I bought it from a truck supply place that realized later that there is a high profit margin and raised their prices accordingly. I've deleted their site from my favorites. If I needed one I'd jump on the one listed at WM.

Ahh I see, go figure..

 

[Timd32]

The return policy for the WM one is pretty good if its not what it says it is, as a retailer Im sure they wont risk their listing for $50. Which is about the uptick from a quality rebuild.

All WM market place retailers run their own return policy, but there are some pretty loose minimums which this seller is better then the minimum requirements.

If price is an issue and you need to save $, here is a place in NJ my Cummins dealer reccomended to me, I trust my local Cummins shop we have worked together on large industrial gen sets for over 15years. If he steers me somewhere it carries weight with me anyway.

https://www.robertsandson.com/product/190-25281/

Their warranty....

 

[BillBaker]

I'm going to get a starter and switch in the Larryb's parts... my gut feeling is telling me it's this. Will post update eventually...

 

[BillBaker]

I got me an original Denso unit (thanks Brett) and did the Larryb's upgrade. We'll see how it goes..

 

[BillBaker]

Burnt again, now I'm picking my brain along with a few others brains