Engine/Transmission (1994 - 1998) crap, that starter contact thing doesn't give you any warning

[Nate]

Yeah my soldering skills aren't the greatest, but I can probably manage. Who did you get the brushes from?

 

[RoryTek]

LarryB's got them.

 

[Bloomy]

Just what RoryTek said. LarryB has them. Soldering isn't that difficult. I needed another hand to keep everything inline. Go to:



Foster Truck





Thomas

 

[4570]

I dont hang out here enough i guess ,who's LarryB and how do i go about getting new starter contacts and brushes from him. Arnie

 

[4570]

Well Duuuhhh ,i clicked on the link in the above message and it took me there ,Thanks . Arnie

 

[Howard Durand]

As LarryB indicated above, battery condition is an important factor in starter performance and life of the contacts. As battery capacity begins to fall off, the closing force of the starter solenoid becomes less, starter current increases and the contacts begin to arc. Eventually they can become hot enough to weld together and destroy the starter.

I think that if the batteries are load tested every year and replaced when needed and connections are kept clean and tight, the starter should last considerably longer with the original contacts.

Larry's larger contacts will provide a greater margin of safety but shouldn't be depended on to offset the eventual effect of poor batteries.

 

[McLaughlin]

The timing of this thread is perfect. My daughter's 96 has started behaving exactly as described by some in the thread. Initially the truck won't start turn over, just a click, then later it will start. We'd had to jump it a couple of times before to get it to start (batteries seemed really low) but then it would be fine for months. I'm beginning to think she has at least one bad battery (we don't know how old they are but more then 4 years) which may have damaged the contacts as Howard just mentioned.

 

[R C Cola]

Starters hang up

I just put the new heavy duty contacts in my starter at 385k . It hung up on me one time and I was able to shut it down by turning off electrical power to the truck with the main power switch I had installed in the Hot lead (red) coming off the battery. One of those cheap (about $10) switches they sell to prevent theft. Just had to lift hood and turn the big red key on the fender well. RC

 

[Berrigan]

Take me to school. I can understand the contacts in the starter sticking, and how that can fry a starter. How can that event damage fuel shut off solenoids and other things?



Can someone walk me thru the process of what happens after the starter contacts stick? Thanks Bill

 

[LarryB]

Read this>> http://fostertruck.com/sol-saverdiode.htm

 

[redram]

It will happen - I fried a shutdown solenoid and it also took out the fusible link back to the driver's side positive battery post - actually melted (actually vaporized) the wire insulation. Fortunately it did not take out anything else - but at $300 for the updated solenoid from Cummins, Dodge dealer wanted 15 bucks for a length of fusible link (took it back and got a generic one that included a mounting eye fro 2. 99). I also had the over tight bolts holding the starter on - had to use a cheater bar over the wrench and it was flexing the wrench body.

I relubed the planetary gear drive while I had it out of the truck.

Time to probably check the brushes after 10 1/2 years.....

 

[Murle]

158,000 mile and still on original starter.....

 

[LarryB]

... ... I also had the over tight bolts holding the starter on - had to use a cheater bar over the wrench and it was flexing the wrench body... ...

The best way I have found is a piece of wood and a small jack to lift up on the end of the wrench. Those SOBs are tight. :{

 

[BigPapa]

158,000 mile and still on original starter.....

Flirtin' with disaster... ... ... ...



It's cheap, easy insurance against a known failure. Better git-r-done!



Scott

 

[Murle]

Flirtin' with disaster... ... ... ...



It's cheap, easy insurance against a known failure. Better git-r-done!



Scott

If it ain't broke don't fix it... ...

 

[BigPapa]

I like it Murle, don't be skeered!



Scott

 

[WDixon27]

only a small fire sorce :-laf

If it ain't broke don't fix it... ...

 

[Murle]

only a small fire sorce :-laf

That is why I have insurance... .

 

[Joe G.]

If it ain't broke don't fix it... ...

It's broke. Why do you think there are so many problems with the starter if it was not broke from the git go? Simple to inspect the thing and fix it if it needs it. I have insurance too, but I try to avoid that kind of hassle.

 

[Howard Durand]

Way back at the biginning of this thread, I stated that I was working on a modification of the circuitry to avoid damage when the starter sticks.

I have it about ready install.

Unfortunately, my starter stuck last week. I had no indication that anything was wrong. Drove about a mile before the solenoid exploded and the engine quit.

The starter and solenoid are both toast. Warmed up the fusible link but it never opened. The fuel shutdown relay is OK but I think I'll replace it and proceed with the modification as planned.



Don't wait for the starter to start clicking, mine never did. Always started on the first revolution. No warning whatsoever.

The contact on the motor side was worn down about half of it's thckness.

The one on the battery side appears to be the one that stuck.

The starter itself is smoked up black and stinks bad.

New starter and solenoid are on the way.



There has been a lot of money and personal inconvenience caused by this abortive scheme and there is no reason it had to be wired this way.