Archived Blown starter solenoid fuse

[ramjet]

Truck won't start, it keeps blowing the starter solenoid 20 amp fuse as soon as the key is turned to start. It happened a few days ago and I replaced the 20 amp fuse and it worked OK til tonight. Now it keeps blowing every new fuse and I'm dead in the water. Unless someone has a easy fix to suggest for me to try, it is going to be a chore to replace the starter on the side of the road. The solenoid doesn't thrust and the starter doesn't move, it just blows the fuse.



Any ideas??

 

[Joe G.]

The first thing to do is to eliminate suspects. Disconnect the big wire to the starter and see what happens. If it stops blowing the fuse then the problem is in the starter. If it still blows the fuse then disconnect the small wire to the starter and see what happens. If it stops blowing the fuse then the problem is in the solenoid. Keep doing that sort of thing until you find it.

 

[DavidMartin]

I had a similar thing happen and it turned out to be worn insulation on the starter wires. The bare wires would short out on the underside of the truck and then the fuse would blow. Hope that this helps.

Dave

 

[fox]

I read here a couple of years ago that the starter contacts cause this when worn. I know it included my truck, and maybe back to 99 MY trucks.

 

[rotohead]

This won't help if you're broken down on the side of the road but preventive maint on that item can be done thru Pete Gould at www.fixnrams.com
or call him for the better starter contacts and plunger and DVD on how to replace those before they go bad. Contacts take a beating on our trucks but are easy to replace. I have a used spare set if it would help you out.
Chuck

 

[ramjet]

Did all the easy external checks, no joy. Pulled the starter. On the workbench back home, on disassembly found the positive contact in solenoid almost totally erroded away. Ran some tests and found that when the solenoid activated the negative contact made and the positive contact did not. When that happens the starter tries to draw current thru the soleniod which is wired on the ground side to the negative contact. That blows the solenoid fuse. If you start to blow your 20 amp solenoid fuse, I would start your repair planning, it appears you may only have a few days left to get to the shop.



Dodge dealer wanted $605 for a REMAN starter plus a $125 core charge, said new not available. I think he can still hear me laughing, I couldn't compose myself enough to ask what the labor would be for him to put it in. I will replace the contacts and clean up or replace the brushes on this one and throw it back in. In the meantime, I did find REMAN Denso and Bosch starters available locally in the $200 to $250 range, so if my rebuild doesn't hold up I know where to go.



Thanks for the help guys, I should be back up by tomorrow.

 

[ramjet]

OK back on the road again.



Here's the benefit of the episode:



I agree with Rotohead that better PM is/was the answer. If you have a 1st or 2nd gen, do a lot of start and stop driving, ~6 to 7 yrs old, and ~80-100K miles or more then pull and replace the contacts. It is cheap and easy. I don't have any experience with these guys, but other TDRs reference Larry B at FosterTruck and Rotohead refers to Pete Gould at www.rixnrams.com (I couldn't get that to work) with his DVD on how to, for the contacts and solenoid plunger replacements.



If you don't want to do that, then replacement of the starter before breakdown or at the first hint of trouble is a good PM. In my look I found that if you want a Denso starter remanufactured by Denso go to www.densoproducts.com. The part no. for the 94-00 2500 & 3500 trucks is 280-0275 @ ~$200 (My past experience with them has been good). Kragen.com has a good selection of new and rebuilt generic and branded starters at a wide price range ~$170-$450.



Do not go to the dealer unless you have a very good sense of humor or a very fat wallet.



Thanks again guys, and remember to fix it before it breaks at the most inopportune time. And also remember, if you drive an auto trans it won't roll start.

 

[rotohead]

OK back on the road again.

Here's the benefit of the episode:

I agree with Rotohead that better PM is/was the answer. If you have a 1st or 2nd gen, do a lot of start and stop driving, ~6 to 7 yrs old, and ~80-100K miles or more then pull and replace the contacts. It is cheap and easy. I don't have any experience with these guys, but other TDRs reference Larry B at FosterTruck and Rotohead refers to Pete Gould at www.rixnrams.com (I couldn't get that to work) with his DVD on how to, for the contacts and solenoid plunger replacements.

If you don't want to do that, then replacement of the starter before breakdown or at the first hint of trouble is a good PM. In my look I found that if you want a Denso starter remanufactured by Denso go to www.densoproducts.com. The part no. for the 94-00 2500 & 3500 trucks is 280-0275 @ ~$200 (My past experience with them has been good). Kragen.com has a good selection of new and rebuilt generic and branded starters at a wide price range ~$170-$450.

Do not go to the dealer unless you have a very good sense of humor or a very fat wallet.

Thanks again guys, and remember to fix it before it breaks at the most inopportune time. And also remember, if you drive an auto trans it won't roll start.

Sorry ramjet... I can't seem to type rite lately... . corrected website address below...
www.fixnrams.com
I've done both Larry B's and Pete Gould's DVD and both are the same contacts/plunger... like you say pretty simple servicing. If you do those items the starter itself is a good one and should last for 200,000 miles or more without a problem.
Chuck

 

[ramjet]

Editorial comment



The correct Website for Peter Gould is www.fixinrams.com

 

[rotohead]

Editorial comment

The correct Website for Peter Gould is www.fixinrams.com

Sorry... . it's that Daylight Savings Time change that screws me up every time.
Chuck