starter issues

[DougE]

Hi everyone. I have read about starter problems on the 02 cummins trucks. Can someone direct me to the sticky about replacing the starter contacts ? My problem is sometimes I turn the key, and get nothing. Second try, truck fires up. Sometimes I get a click, and no fire up until second try. Someone told me this could be a relay in the power distribution box. Others have said, I need a new starter. Kinda wondering because it seems to start on second try when this happens. However, sometimes, I turn the key and she fires right up. So my problem is intermittent. Crazy I know. Could this be solved by replacing the contacts in the starter ? I should also mention, this truck is 19 years old, has 200K miles, and the starter and relays have never been replaced. New Batteries first of the year. I'm cheap and frugal, so want the least expensive fix. Thanks

 

[BigPapa]

Larry B’s. This should tell you what you need to know.

http://www.fostertruck.com/dodge/starters/rebuild-kits.html

I would get them from Geno’s Garage.

 

[DougE]

Thanks BigPapa, I looked into them. I appreciate your help DougE

 

[GAmes]

I carry a set of contacts from Larry B in my toolbox all the time. My experience with failure isn't intermittent, it is every start. You didn't indicate how fast the starter is spinning the engine over, a vital key. Replacing the contacts is a good measure, but I'm not sure they are the issue.

 

[DavidC]

Swapping the relay in the PDC would be the first thing. Start with the easy part.

 

[JR]

As a start check and if necessary clean all of your connections. Starter, battery cable, ground, etc.

 

[DougE]

Thanks gentlemen for your replies. It was indeed the starter, and more than likely the contacts. I couldn't wait the down time for me to crawl my tired old ass under the truck to replace it so went to the the shop, and I reluctantly overpaid for a rebuilt nippondenso starter. It came with a lifetime warranty so, at least thats a good thing. I had to turn in my original for the core of $125.00 otherwise I'd have kept it and put in the oversized contacts from Genos or Larry B. and kept it. Getting old sucks. At least I got a rebuilt Nippon Denso OE starter, and before the install, we pulled the little cover off. It did indeed have the oversized contacts, so, I should be good to go. I learned more about starters, contacts, brushes ect than I ever wanted to know, from youtube, Larry B and Genos, but, hey if you young guys are up for it, they are an easy fix. Long live the 2nd gen 5.9 24 V diesel.