man down.... need help!!

[Todd T]

my now retired boss has just lost his starter and fuel shutoff valve do to what we believe, was the ignition switch failing.



the symtoms were it wouldnt shut off when you turned the key off, and sometimes it wouldnt stop the starter motor after the truck had started.



he had an appointment to go to the dealer today, but it did it again on Saturday and he couldnt get it to shut off or quit running the starter. he had to finnally pull the battery cables to kill it.



I took out the starter and fuel shutoff valve that we know of, and he is now looking for parts. the dodge dealer wants $420 for a shut off valve. I told him to check with a cummins dealer. any Ideas.



he needs a starter too. we are in Illinois near St Louis Mo. can he rebuild the starter or should he just spring for a new one?



he replaced the ignition switch yesterday, himself.

 

[Dieselnerd]

I believe the problem you've described is usually caused by the starter solenoid hanging up, not the ignition switch. Do a search and I think you will find several threads about the very same problem. I think they mention kits to rebuild the solenoid if your starter itself is still OK.

 

[Todd T]

thanks Ron, i did a search and read up real fast, youre right its the starter solenoid they claim that is doing it. although he did take out his fuel shutoff too, we are going to pull the starter and check it out before he buys a new/reman'd one.



I also gave him directions for killng it, if it happens again.



this is the first trouble he has had with this truck since new in 96. he now has 130,000+ on it and we are planning to turn him up a little in september, at our next meeting.



that is the cool thing about these trucks, he's 62, I'm 30 and my youngest brother is 19 and we are all, ate up over these things.

 

[RHARVEY]

What is the steps to shut it down if the key doesn't do it??? My truck works like a dream, but its knowledge if someone else needs it... .





Rick

 

[Jeff Burke]

Before you go and replace the shut-down solenoid, make sure it is truly the culprit. I have to agree, it sounds like a starter, not the fuel shut-down. That's about a $400 mistake you may be able to avoid.

 

[Todd T]

thanks Jeff, but the culprit took out the fuel solenoid when it acted up. it smoked the fuel solenoid and we think the starter. he is pulling it out now and we plan to tear it open and see if we can do bench rebuild on it.



the shutdown process as i understand it is;



1. pull the fuel solenoid relay first. this will kill the engine and stop the power from back feeding into the fuel relay and smoking it.



2. pull the relay for the starter, if this doesnt stop the starter then pull the battery cables. or sometimes beating the life out of the starter solenoid (under truck, also a good reason to kill engine first) will free it.



PS: the dealer wants $420 for a new fuel solenoid + had to order it, and Cummins dealer wants $260 and has 7 in stock.



guess who got a return call and sale!!

 

[jimk]

ground switch

I had that happen to me once also,but no damage. I had thought to install a switch in the ground like most heavy equipment, It helps stop batterys from discharging while the engine is stoped, (diodes in the alternator) shorts that cause fires and other bad things. You would have to power your computer, I think , some how. Or just use it when you have a starter run a way. You can open the hood turn the switch to open grounding switch after you turn off your ignition switch and the starter will stop. A lot faster than trying to get the cables off.

Originally posted by Todd T

thanks Jeff, but the culprit took out the fuel solenoid when it acted up. it smoked the fuel solenoid and we think the starter. he is pulling it out now and we plan to tear it open and see if we can do bench rebuild on it.



the shutdown process as i understand it is;



1. pull the fuel solenoid relay first. this will kill the engine and stop the power from back feeding into the fuel relay and smoking it.



2. pull the relay for the starter, if this doesnt stop the starter then pull the battery cables. or sometimes beating the life out of the starter solenoid (under truck, also a good reason to kill engine first) will free it.



PS: the dealer wants $420 for a new fuel solenoid + had to order it, and Cummins dealer wants $260 and has 7 in stock.



guess who got a return call and sale!!

 

[Missouri Mule]

I believe the basis to the engine run is the starter solenoid specifically the battery cable side contact point. Moisture or diesel fuel gets into starter solenoid. Theory only I don't know of any one that has torn starter down and found signs of diesel.



One way I got the starter to disengage was to let the clutch in and out, this knocked the starter gear back into starter.

Won't work for autos next best thing is cable disconnect on ground cable.





I had engine run on three times while starting truck, starter stuck all three. Had engine run on once that starter did not stick. During this period my fuel return line was leaking. Fixed fuel lines and replaced contact point. No engine run on since.

 

[Deezul1]

I installed 2, (1 on ea battery) cable disconnecters. They have a knob that is like a switch that opens the electrical connection internally with a 1/4 turn. unscrew the knob and take it with you and no one can start your truck. I got mine at Harbor Frieght for $9. 99 ea.

 

[inarush76]

starter kit

Here is a number to a place in AZ. that sells a kit for the contacts and such in the starter. Looks like a nice kit. Only around 25-30 dollars as I recall. I bought one as a pre-emptive strike against ole' Murphy.



James Northum

DTT dealer/installer-Texas

 

[inarush76]

DUH!

Guess it would help if I included the #! Diesel Electric Serv.

520-836-8231 Sorry guys.

James

 

[Todd T]

Thanks for all your help, we got him up and running.



it took out the fuel shutoff valve, and the starter was stuck when we took it off. we put a new shutoff vavle and starter on it. he got the parts from a Cummins dealer and saved over $400 from what a Dodge dealer wanted.



they didnt take his starter in on a core and didnt charge for it( i think the counter guy was new)



so what i would like to do is put a rebuild on it and shelf it for a spare. or if someone on here would need it.





I will tell him about the disconnect cables, thats a good Idea.



thanks again,

Todd T.