Engine/Transmission (1994 - 1998) Oversize Starter Contacts

[Dieselnerd]

I just installed the oversize starter contact kit with plunger from fellow member LarryB. I dropped my front driveshaft to make more room but an 800 pound gorilla must have tightened those 3 bolts holding the starter on. They broke loose after I got the longest piece of pipe that would fit in the close quarters on the end of my wrench. Replacing the contacts is easy once the starter is out. One caution, after I had the cover off where the contacts go, and had the plunger out, I happened to tilt the starter and thought I heard something drop out. I looked all over the floor of my garage and didn't see anything but had the nagging thought I better look closer since I knew I heard something drop. I looked at the end of the plunger and it has a concave dimple on the end that looked like it would fit a ball bearing. I did another "hunt" and found a large ball bearing that had rolled under a piece of cardboard. Sure enough, it fit right in the hole where the plunger fits. After I had the starter out I could see the fuel return hose pretty good and although I had changed it earlier this year, I thought I would put in a longer return hose to route it away from the heat of the engine. Now my return hose is routed to the outside of the fuel filter and doesn't come close to the heat of the motor and is easy to inspect if I have a fuel prime problem in the future.

 

[Todd T]

Good post Ron, Ill have to look at that return line routing.



I PM'ed you about your transmission

 

[RBrunson]

Ball

Ron, thanks for confirming what I thought about the little ball bearing. I didn't hear or see it fall out of mine but found it on the bench and wondered if it went in the plunger hole. It looked like it fit on the end of the plunger so I installed it.

Also about the bolts, HOLY COW do they have to be that tight! You guys think that its tough getting your first oil filter off is tough. I twisted the head on my Craftsman box wrench then I found an old German brand that I could use a short cheater bar on... . isn't it fun working on our trucks.