Solenoid/Starter or Ign. Switch?

[KEENO]

I've been having Intermittent Starting issues for 2 weeks now.....



Known:



> I've have a new 1125CCA Deka Battery.

> Clean Terminals

> Confirmed Ground

> Continuity run on all wires/Good

> New Super Contacts/Plunger Kit Installed.

> Good Clutch Interupt Switch



"Larry B" suggested that I jump the sarter using the Old Screwdriver Trick next time it didn't start. I just did that w/ the help of a friend and it didn't start.



Procedure:



Ignition Switch on in "RUN" Position

Starter Relay 'clicks'

Placed (1) screwdriver on small, solenoid post

Placed (2) screwdriver on large, main Positive (+) side Post on Starter



Then... ... .



Touched the screwdriver shafts together as a 'circuit/short'.



Result:



1st attempt: No Spark

2nd attempt: Weak Spark/ No Rotation of Starter

3rd attempt: Strong Spark/No Rotation of Starter

4th attempt: Whacked Starter/Strong Spark/Starter turned over.



Question:



Starter/solenoid (Super Contacts installed)???



OR



Ignition Switch???



(Note: Starter has 280,000 mile on it)



Advice welcomed..... I'm frustrated



KEENO

 

[bgilbert]

Keeno, I just went threw this, it has to be the brushes in your starter, take the starter apart- the big part, not the solenoid-top part. You well see that the brushes are probly gone, worn to nothing. I done replaced my ignition switch, starter relay, new super contacts, plunger and same thing, had to keep whacking the starter for it to engage. Took it apart and it was full of black powder, what was left of the brushes. Sounds like you're like me, we dont want to admit its the starter!! But it IS. It will need rebuilt, as Philip said in one of my starter issues post, brushes worn are a result of a 'high mileage starter'.



BTW for you and the rest of the forum a easier way to do the screwdriver across the two starter posts procedure/test, take a set of jumper cables, hook one on the big pos bat post and one on the small solenoid post, then with the other end of the jumper cables you can simply touch the two together to get the starter to turn. This way you dont have the fear of the big spark or lay under the truck. Bill

 

[blacksheepdiesel]

KEENO,



When you say "Confirmed Ground" do you mean to the engine or the starter? And, do you mean continuity or a good solid current path? I have seen a starter not work or work intermittently because the starter was "grounded" but it wasn't "GROUNDED". For giggles before you pull the starter off and apart you might want to try running a heavy ground wire from the battery and crimp it behind one of the bolts to confirm that you have a good ground.



Also, I have seen a rebuilt starter have enough new paint on it that it would work sometimes, somtimes not. Since yours isn't rebuilt I doubt this is the case. But this condition could also be caused by having too much grit, grime, grease, oil, etc, between the starter and bellhousing.

 

[hdm48]

Bgilbert is the who is right.

 

[LarryB]

Keeno

I'm feeling your frustration man!



In fact, I'm sending you a new set of brushes tomorrow at no charge. E-mail me your address again would ya?



We'll get this thing solved one way or another.



Larry

 

[KEENO]

Thanks Guys!

Thanks Guys!



You're awesome! I have a date w/ the "Brush Doctor" up in Nashville in the morning! He has brushes for $10. 00 and will install for another $10. 00. It has been mentioned that the Armature (sp?) needs to be turned for proper brush seating. For $20. 00 I'll let a professional handle the job!



The Starter has been in the back of the truck for most of the day and the (+) leads taped & zip tied to prevent ARC Welding themselves to anything important. Good thing it's a stick & I live in the 'Hills' of Tennessee!



LarryB... ... Thanks for the Brush offer!!! If this $20 investment doesn't fix it..... Look for an order on your website for a new Starter.



Bgilbert..... Thanks for all of the advice and convincing me it's brushes!



If this doesn't fix it... ..... I'll be asking more questions w/ new Headings. Ign. Sw. ?



Thanks gang... ... KEENO

 

[KEENO]

Brushes Baby!

Bglibert wins a year supply of Turtle Wax and the Alligator Luggage for his correct response. Also... ... Parting gifts of Rice-a-Roni for all participating contestants!



I had the brushes replaced in my ND starter today up in Nashville for $20. 00 total (parts/labor & armature dressing incl. )



She's starting like a CHAMP! For the price of LarryB's Super Contacts ($34. 95) & $20. 00 in brushes... ... I feel like I have a starter that will hang w/ me for another 100,000 miles.



Maybe it's too soon to celebrate, but I absolutely love when my dependable Cummins starts w/ the flick of a switch!



Thanks to all for seeing me thru this intermittent starting issue!



KEENO

 

[bgilbert]

Keeno, I'm happy to hear your up and running again, its such a great sound to hear our trucks fire up in an instant. I'll have to take my spare- well the starter that will be for my 91- to the starter shop and get some brushes and have the armature polished etc, I hope there prices are comparable to the ones you got!! I didnt know it would be so cheap. Bill