Engine/Transmission (1994 - 1998) Starter Contacts.

[rlittle]

It appears as if my Starter is about to die. Turn the key and nothing. Turn it again and the thing will start.

I suspect that my contacts are about to give it up as the truck (96) has about 75K on it.

I understand that there is someone here in Arizona that sells a contact repair kit. Want one in the tool box if this thing decides to give it up on the road.

Any suggestions on where to go to get a kit.

Rollie

 

[illflem]

Try here



http://www.fostertruck.com/dodge/default.htm

 

[JConley]

Just replaced mine a few weeks ago. Most likely you will only need the one contact. Its an easy repair. The hardest part is getting the starter off since it is torqued to 10,000 ft/lbs.



hint... take off and replace the top bolt first. When you are done cussing, the other two are easy.

 

[shendren]

75k mi suggests that your contacts are probably shot. i would not wait until you have to do it "on the road" with poor light. good luck.

 

[fest3er]

Hmmm. At 125K miles, I should be looking to change mine. But then, around 40K of those miles had perhaps six starts per 1500 miles, so they might not be so bad after all. But a little PM can't hurt.

Fest3er

 

[wcjp]

I did my contacts at 140,000miles. One of them was well past it's service life. Very easy to do. I used LarryB's.

 

[Bob Ellithorpe]

Torque

J Conley; How can you get 10,000 ft. lbs on a 10mm wrench. I'll grant you that the bolts are tight and I had to use a cheater bar.

 

[illflem]

Re: Torque

Originally posted by Bob Ellithorpe

J Conley; How can you get 10,000 ft. lbs on a 10mm wrench. I'll grant you that the bolts are tight and I had to use a cheater bar.

The way I do it is with a 2. 5 ton hydraulic bottle jack on the wrench. That's only 5000 or so ft/lbs but seems to work.

 

[vssman]

Definately get the contacts now, before the starter dies. I had a hell of a time getting a local auto electric shop to sell me just the $4. 00 contacts. It seems all but one would only sell me the starter or rebuild it for me. If I had some foresight - I would have ordered the contacts before the starter crapped out. Oh by the way, the starter will either not work or ... . hang up and you won't be able to turn the truck off until the wires going to the starter & fuel shutoff solenoid catch fire. I now ride around with a mallet just in case senerio two happens.

 

[rdrose]

cost 6.00 bucks

i found a gut that rebuild starters out the back of a napa store. didn't speak real good but the pictures in his starter book did the trick. had the reg starter contacts and right next to that picture was the one's they call the super contact. 6 bucks and out the door should of got a plunger but didn't just shined her up on the wire wheel and everything works great.

 

[Ben Rumson]

Don't trade your Starter for a rebuild

Your starter is a very good starter and can be rebuilt and serviced. Keep your original.



Far better off to keep it and service it than trade it in at a parts store for a replacement that could be way inferrior to your HD stock starter.

 

[DavidGardner]

Did mine a couple of weeks ago. Bought them from Larry B.

They are heavy duty and easy to do. Hardest part is removing the 3 10mm bolts holding it on. The replacement kit has very good directions or you could probably down load them from Larry B"s website. I would not wait until it pukes and you have to do it

in a parking lot in the rain or snow. Just do it now where you can control the environment and conditions.

Just my . 02 cents worth.

 

[Todd T]

I personally have seen the fuel shut off and starter ($400+) go up in smoke from a $3 dollar part wearing out. I think contacts and plungers should be on everyones 75K maintenance list.

 

[Joe G.]

Bob,



How did you get a cheater bar in there? I can barely get my hand up there.



If my starter contacts ever give up I'm going with Larryb's. I took a look in my starter about 70K miles ago and found one of them was pretty thin. So being a cheapo type from the getgo, I found a big copper bolt in my garage junk. It was from an electric panel from a fish boat. I hammered it flat and cut a contact out of it. I only expected it to last until I could get the right replacement. Every other oil change service I pull the starter and check my homemade contract. The crazy thing is barely dirty. I have no idea what kind of copper it's made from, but it sure is lasting. 210K miles on the Green Monster so far.

 

[bmoeller]

Replaced the original contacts and plunger at 152,000 miles(mostly highway). Started have trouble starting the truck, but the new Larry B parts work great. The starter seems to spin over alot faster now.

 

[JConley]

I hope you dont think I was serious about the torque... In reality, I used a hammer

 

[Bill Lins]

Originally posted by rlittle

I understand that there is someone here in Arizona that sells a contact repair kit. Rollie

I got mine from Diesel Electric Service Co. in Casa Grande, AZ. (800) 836-8231

 

[Ben Rumson]

Originally posted by Joe G.



... I found a big copper bolt in my garage junk. It was from an electric panel from a fish boat. I hammered it flat and cut a contact out of it.

Joe, that's Fantastic !!! Way to go Joe!



That's the kind of ingenuity that spearates the boys from the men. They're not afraid to try something new. That same kind of ingenuity is what LarryB used to come up with the Super Starter Contacts. Way to go Larry! Thanks for developing the idea further.



For those with oxy/acelelene:

A firends Dad resurfaces his contacts using a copper brazing rod - similar to recaping a tire. Then he smooths and shapes the surface to what he wants.



I replaced one contact at 120k. When the next one goes, I'm calling LarryB. He's been a great support to TDR Members and I (personally) think it's important to support him in return.



Good thread.