Engine/Transmission (1998.5 - 2002) Starter solenoid contact story...

[IdahoJim]

So, after 240,000 miles, the Dodge starts getting hard to start. Bought the kit from Genos with the CD. The kit shows up, so I crawl into the Dodge and get the starter out (we know what a fun project that is... LOL). I get the solenoid out, and find out the so-called "super size" contacts are smaller than the factory contacts. Since without a starter the Dodge is unusable, I go ahead and install them anyway. The starter now works albeit not as high RPMS as original. I call Genos to give them a "heads up" and the guy has me call Larry B's. Larry tells me he didn't make the kit I got from Genos, but takes my address, and says he'll send me a set of his Super Size contacts... . now THAT is a standup guy. I call Genos, and the guy is still reluctant to admit they screwed-up, but finally apologizes that I have to pull the starter again. I think Larry B. 's is going to get what business I have from here on out. If you buy from Genos, I would strongly suggest you make sure of the size of contacts you get in the kit. Both contacts should flare out to about 1. 2" wide from the roughly . 8"-. 9" width at the lug hole. You may save yourself doing the job twice, like me.

Or, just buy the kit from Larry B. http://stores.ebay.com/LarryBs-12-Valve-Dodge

Jim

 

[Cosmo]

Good to know!

For later this decade when I need to go through my starter...

 

[IdahoJim]

Good to know!

For later this decade when I need to go through my starter...

I'm glad you won't need to for awhile, Cosmo. With my new smaller contacts, mine is still turning too slow. I decided, when the larger contacts get here, and I have to pull the starter again, I might as well replace the brushes, too. I've been clear through everything else... grounds, batteries, clamps, etc. The brushes are about the only other thing I can think of. Talking to Larry, he said since my starter is original, and has never been worked-on, the brushes are probably due.
All the best,
jim

 

[Cosmo]

Yeah, definitely due. My truck went from starting great, to chugging a little the next day, to taking a few attempts to get it to start the next day, so I just bought a new starter. I would have rather bought net contacts and brushes, but I didn't have time to wait for stuff to show up in the mail.

 

[DMcLeod]

Amazing you got 240,000 miles out of your starter. I just rebuilt mine near 200,000 miles, and did not replace brushes. They will go until the next rebuild. For some reason the dodge starters wear those contacts, and usually only one (weird). Just because the starter is original and never been worked doesn't necessarily mean brushes are due. Just my 2cents.

 

[IdahoJim]

Amazing you got 240,000 miles out of your starter. I just rebuilt mine near 200,000 miles, and did not replace brushes. They will go until the next rebuild. For some reason the dodge starters wear those contacts, and usually only one (weird). Just because the starter is original and never been worked doesn't necessarily mean brushes are due. Just my 2cents.

The miles aren't the only reason I think the brushes are due. It's not generating the RPM's it should, even with new, albeit smaller, contacts. After going through everything else, the brushes are all that's left to be causing the problem. We'll soon find out... the larger contacts are on the way, and once the brushes show up, I'll be pulling the starter, again. This time I'll tear the motor down and check the brushes and bearings, along with installing the large contacts. I'll report back what I find.
Jim

 

[IdahoJim]

Wow..... got the new contacts from Genos, as it turns out. Also, while waiting on delivery, I decided to R&R the brushes, too. Pulled the starter yesterday when the parts showed up. Got the contacts installed, but had to wait on delivery of a pencil torch to solder the brushes in. That showed up late yesterday, so installed brushes last night. Put it together today, and what a DIFFERENCE. This truck has always started really quick, but I guess, over the miles, it had slowed a little, and I just didn't notice. Hit the key today, and it was running... I doubt that starter turned for a full second. I'm definitely liking this. I can now pull the starter in 20 minutes, too. It's an ugly job, but once done is not that difficult. The solenoid was very clean, but the motor itself was a mess... just full of oily dirt, I assume from blow-by from the crankcase vent bottle. I chucked the armature in the lathe and cleaned up the commutator while I had everything apart.

The original starter went 247, 600 miles... . no bad. I probably could have foregone the brush replacement, but would have been back in there in 50,000 miles, or so... . there was only about 1/16"-1'8" of movement left in the brush leads.

Jim