Bad starter solenoid fix

[Deezul1]

Here is a way to save some big bucks. This fix was posted some time ago and I cant give credit where due cause I cant remember his name, but it saved me a bunch today. Got in the truck and oh oh click, click and finally it started and it did it again next time and then the starter would not dis engage you could hear it running along with the engine. Shut the key off and nope wasnt gonna do that, no shut down. Put it in 1st gear and let the clutch out, engine died and as soon as I put the clutch in the maniac starter was still going and restarted the truck mind you the key was off all this time. So I started disconnecting batteries and the whole time starter and engine are both running, and it finally quit.

Starter prices will give you heart failure, called a local starter rebuilder and the solenoid plunger and contacts were $31. 00 and it works great and is easy change them out

 

[CumminsPower98]

My cousin's '97 CTD just started doing the same thing (click, click... ) so I told him he better keep a wrench and screw driver handy under his seat until we get parts since these things will stick on. My problem is I don't know where to get the rebuild kit for the solenoid. I guess I will have to do some calling around.

 

[Bob Ellithorpe]

Starter Rebuild

Does anyone know where parts such as brushes and bushings(bearings) can be purchased for these starters?? Also parts for the solenoid.

 

[MikeR]

There was an article written in the TDR issue 25 member to member column.

Robert Brown wrote in his article that he got his parts from:

Keith Swearigan's Diesel Electric Service

917 Pinal Ave

Casa Grande, AZ

520-836-8231



Hope this helps.



-Mike

 

[Deezul1]

Thats the place I was thinking about, they take credit cards and ship all over.

Ask your local auto parts store about any local rebuilders, they will have parts.

 

[HEMI®Dart]

My starter was acting up too. I rebulit it with Keith's Solenoid rebulit kit. The complete rebulid kit.



It worked ok for 6 months, than it started acting up again. I said screw it and got a rebuilt starter. Lifetime warranty.

 

[JIM S.]

I work with "cumminspower98"s cousin and saw the thing up close... had to kinda laugh a bit... . it is just a large version of what the toyota trucks have... same shape, same internal parts... just bigger! both are made by DENSO so it stands to reason. anyway I had the same problem on my toy back then so I am glad to know its easy and cheap. theoreticly one could just get two flat copper tabs and bend them and drill a hole and BINGO... but will save that till its my turn. . when its my turn I might try and if it works I will tell how it works! . . JIM

 

[danandamy]

Tough mamajamma's

I wouldn't worry about doing brushes and bushings. I would just about guarantee you that when the rebuilders for the parts stores get these starters in they do the solenoid fix clean them up and send them back out. These little denso's are tough suckers. Think about how long that starter was running with the engine going. I've had Ford gasser starters go through this for alot less time and they were up in smoke. Had to fix mine last weekend on the 4x4, yep contacts were toast. If you have 100,000 miles on your rig, you might as well do the fix as a part of maintainance.

 

[Missouri Mule]

To those who care?



Usually contact points are all you need, but if you want to put in a new plunger go ahead.

Look in the yellow pages find listing for auto electric or starer/alternator repair. Bring the starter with you take the contact point(s) out ask the head guy if he as any that size( in my case I was able to get one for $8 bucks and that put me back on the road again). I'm going to order a few pairs from that electric place in Arizona just to have on hand.



When the starter/engine runs on pulling the driver's side battery cable off is not going to do any thing. Why ? Because your passenger side battery cable is hooked to it. Meaning unless you are super man your not going to get them both off before the starter goes. ( power is going to flow through the driver's side battery cable from the passenger battery/ cable- starter still will be getting power. )



Deezul 1, you had the right idea but wrong gear ( it still mite not of worked but did for me once) You neeed to try high gear(4rth or 5th) let clutch in and out, you want a rocking motion. The theory(mine- even though mite not be same cause) is that if you kick the starter gear back at starter it mite knock a lever(name?) back into the plunger making the plunger disengage with conacts.



Here a short version from auto repair book for dummies.

"Sometimes the stater driver pinion gear will jam in the engaged postion. If engine is running you will probalby hear an unusual noise which is the starter or starter gear being driven by the engine. ..... A jammed drive can be freed by putting the trans in high gear and rocking the car forward and backward. This is not possible with an auto trans and the starter will have to removed to free the drive. "



If you want to stop the starter from getting power take off the battery cable at the starter. It is real easy to reach its the one on the bottom of the starter/solenoid.



Sorry for the novel(long post) but I was going thru withdrawl.

 

[Bob Ellithorpe]

Starter Parts

Does anyone know if Keith Swearigans Diesel Electric Service in Casa,Grande,AZ. has an e-mail address ??

 

[MikeR]

Jim S,

You're correct on your description. I work at a Honda dealer and the Denso starters on the Hondas look exactly the same only smaller.

We see many cars every week that only need the contacts replaced... usually between 120k-150k miles.



Just like the Didge dealer,Honda doesn't sell contacts,so we go to a local rebuiler and buy a bunch to offer a cheaper alternative. I had the rebuilder send me a set for my Dodges.



-Mike

 

[Deezul1]

After my starter run on problem I decided an alternative disconnect method was needed for the batteries. I found a disconnect device that goes on the battery terminal and the cable goes onto this device and it has a knob that when turned about a half turn will disconnect the battery and if you unscrew the knob completly and remove it there is no way to start the truck with out rearranging the cables again. Good for parking in bad areas.

 

[Missouri Mule]

Bob,

I believe they have web site. I know they have address in one to the TDR's publication.



Keith Swearingen's Diesel Electric Servicd Company

917 North Pinal AQvenue Casa Grande AZ

phone- 520-836-8231



Tried web search to no avail will try archives.



Bob did not find any web addresses.

Call the number above or try to find auto electric service in your area.

 

[Missouri Mule]

Deezul 1,

Where did you install the quick disconnect on the cable?



Did you install so it disconnects both cables (power since they are tied in together?)

 

[Deezul1]

Missouri Mule

I put 1 on each battery at the ground cable, it goes between the post and the cable

 

[Missouri Mule]

I'm proud of you! Job well done. Even better than putting them on the positive cables.

 

[danandamy]

Run on!

OH CRAP! Hopped in the mighty Ram to leave work this afternoon and the starter hung on! I just did the solenoid rebuild last weekend, so that's not what caused it. The motor wouldn't shut off either. I replaced the starter relay itself but it did it again after that. Man, I'm wondering if the double relay on the firewall can make it do this as well. Somewhere it's getting a feedback loop going. Any ideas anyone?