starter

[SJohnson]

1996 3500 5. 9 diesel ,has anybody had trouble with starter not engaging when the key is in the start position ? all i get is a click sound after about 15 to 20 tries it will finally engage,any suggestions will be appreciated.

 

[Dan_69GTX]

You need new starter contacts.



Do a search to find the part numbers and who you can order them from.



I got mine locally.

Dan

 

[Howard Durand]

The starter is easy to remove. Disconnect the batteries, disconnect the two electrical cables at the starter and remove three bolts. You will need a 12 point, 10 mm box end wrench or socket for the mounting bolts.

 

[Oliver88]

Starter parts

Diesel Electric Service in Arizona has the parts for the solenoid repair. They are 29. 50 plus S&H. Phone number: (520) 836-8231.

Greg

 

[bighammer]

Get it fixed before it stays engaged.

 

[jimk]

I had the same problems as you are having, including the starter run- a- way. As It turns out what is happening is the contacts wear uneven and the plunger is forced to wedge in the bore or that is what was told to me.

Today I got my new contact kit in and I compaired the contacts to a few left over from a turbodiesel Toyota 4x4. I am glad I kept the parts now. as the contacts looked the same as the original Toyota contacts. I also had some bigger contacts than the original ons which had a lot better contact in my Toyota, And I am going to use them in the Cummins as they worked better than the Factory contacts.

I made a mandrel to burnish the contacts to get a good contact. I found out very quickly that you need to install the contacts a flat as I could. I used anti-seize on the contacts retaining bolts threads.

When the brushes wear out I think that there is a company call Helwig that sell brushes by a given size, or you can file down some larger brushes to fit as I have done this several times over the last 20 years or so.

You can take a pocket knife and peal out the seal on the bearings and smear a little grease and put the seal back in. They will run a long time like with a little grease in them.

One last thing, make sure that the starter relay is giving the pull in coil 12 volts . LOL Jim