Archived 99 will not start, (starter does not engage).

[BigDaddy]

My 99 2500 2wd auto w/150K has been intermittently not starting over the last two months. The lights and instruments all work fine, but the starter is not engaging. I hear a click (the starter relay?) when I turn the ignition key, but the starter does not crank.



I thought it was the starter contacts and changed those with Larry B’s contacts and plunger (the old contacts were thin), but the symptoms of not starting became more and more frequent over time. Now, the starter will not crank at all so, I am dead in the driveway :{



This is what I have done so far:



1. Checked all the fuses and relays in the Power Distribution box.

2. Swapped the Park/Neutral Safety switch with the one in my 2K.

3. Swapped the starter with the one in my 2K.

4. Swapped the Ignition switch assembly with the one in my 2K.

5. Replaced batteries a month ago, not because of this problem, but because of age.



I have searched the 911 archives and have not found anything. My next move is to methodically check all the wires in the start system visually for any loose connections or broken wires.



I am at my wits ends



Any help, any suggestions, are greatly appreciated.



TIA,



Joe

 

[JFaughn]

It sounds like you looked into most of the regular suspects .
Use a test lite & wiring diagram , 2nd person to turn key & check all related wiring from starter to ing sw , make sure to double check the things you already looked at , there are defective parts out there & a chance at a mistake .
In a emergency you could use jumper cables screw driver to jump at starter solenoid .

 

[BigDaddy]

John,



The parts I used came from a working truck so; I know the parts are good.



I am in the process now of checking wires visually. I do not have a wiring diagram for a 99, but the next thing will be to use a test light and an ohm meter.



Thanks for the reply.



Joe

 

[icman95]

May be a silly question considering all the work you've already done but here goes:



Could it be a bad battery cable? Maybe the hot one to the starter is loose, broken, corroded somewhere that you might not have seen yet. Bad ground somewhere? If the wire is just slightly bad it might be provided enough juice to click the relay, but not enough to turn the motor. Good luck.

 

[ROADWARRIOR]

I've read of other people having a no start condition and they ended up finding a wire pulling out of a connector in the steering column.



Dan

 

[RHARVEY]

there is a 20 amp fuse under the hood in that black box on the drivers fender. . Check that. My wifes 2000 did something like that. . I figured it was the brushes in the starter so I put in the set of Larry B starter contacts. . still would not start. By the way the contacts were bad. .

So I started looking and found this fuse blown because of the contacts. .



Rick

 

[MAllen1]

I would check the resistance in the wires (while u r at it, check connections again). Make sure you don't have an unusual amount of resistance coming off the wires, especially coming off the engine.

 

[BK]

Do you have a volt meter?

Not just a test light, but a voltmeter.

If the voltage is too low (as a bad ground or bad cable could cause), the starter will have it's problems engaging.



Are you getting 12v down to the starter when you try and turn her over. .



I've sent you a PM.



-Bob

 

[Missouri Mule]

You should have a starter relay inside of the PDC,check that out.



You can use a solid wire (house wire) and touch one end in the female terminal towards battery and the other end in the female terminal towards cab that should turn it over unless there are bad wires/connections or the starter is bad.

 

[BigDaddy]

Hi All,



Thank you for all the help and suggestions.



I did not get a chance to work on the truck today because it rained all day here in New England and I do not have a garage. Tomorrow the weather should be nice and I plan on using your suggestions.



I will keep you posted as to how I make out.



Joe

 

[jmadden]

Check the voltage of the batteries... just becuase they are new... .

Check the grounds... I've used jumper cables to ground in addition to the battery cable to see if this resolves issues.

Test the cables w/ a volt meter.

Check for 12v at the starter.



Apparently more of the sme ideas others have piped in with.

 

[RON'S RAM]

Hi All,



Thank you for all the help and suggestions.



I did not get a chance to work on the truck today because it rained all day here in New England and I do not have a garage. Tomorrow the weather should be nice and I plan on using your suggestions.



I will keep you posted as to how I make out.



Joe

Hi Joe,

any luck yet? I think the best place to start now is to go to the starter with a voltage meter. See if you have 12 volts from the big terminal to ground. If so, have someone turn the key to the start position and see if you then get 12 volts from the small terminal to ground. If not, then I would start looking for a bad connection. If you do have 12 volts to ground normally there might be a problem with the starter, but since you tried another one & it did the same thing, maybe it is a bad ground. I have a wiring diagram for a 97 if that will help you. Good luck,

Ron

 

[BigDaddy]

Hi All,



Well, it did not take me long to find the problem today.



I broke out the multimeter and started with voltage checks at the starter. With the ignition switch in the “on” position, I read 12v at the large positive terminal. With the ignition switch depressed to the start position, I read 9v at the black 14 ga. wire and I could distinctively hear the starter relay closing, but the starter did not turn the engine over.



I then checked the large positive terminal with the ignition switch depressed to the start position and I saw a huge voltage drop (to 2v). I then visually checked the large positive cable from the battery positive terminal to the starter and did not see anything wrong, until I grabbed and wiggled the cable at the starter connection.



The cable was loose at the crimp on the terminal lug and upon further inspection the cable was corroded where it was improperly crimped. I was able to pull the wire from the terminal lug end.



Furthermore, the cable terminal lug did not have the protective cover at the starter connection so, I suspect the terminal lug was improperly crimped from the factory and since it was missing the protective cover it was the perfect environment for electrolytic action (corrosion) to set up.



I cleaned the cable end, replaced the terminal lug and installed the terminal lug connection with a protective cover.



I greatly appreciate everyone’s help and I wish you all the best.



Best regards,



Joe

 

[BK]

Joe, thnx for the update, glad to see your trouble shooting skills are nice and sharp. Good find.



-Bob