Archived starting problems

[mazdarotary]

Hello all,My brother-in-law is having problems with his 95 Cummins 2500. When he tries to start it he just gets a clicking noise and no movement from the starter. Eventually after a few tries the truck turns over nice and fast and fires up. He has replaced the batteries,and the starter to no avail. He told me that he swaped a relay for the starter with another one under the hood just to make sure the relay was ok and the problem was still there. I don't know anything about the cummins yet(i'm in the process of buying a 92),but i am pretty mechanically inclined(mazda rotaries are my specialty)and he is very mechanically inclined. What should we look at first?He said he has a chilton manual. I have found from prior experience(with the mazda)that the chilton is a o. k. guidline but not nearly as good as a factory manual. Can the manuals for these truck still be had?Thanks for the input.





Chris

soon to be 92 D250 cummins owner hopefully Oo.

 

[rkubicki]

Chris,



Sometimes a problem like this can be caused by oils, impurites, etc. between one of the battery posts and its teminal or the terminal is too loose... . Remove the terminal and clean it with a battery terminal brush... After reassembly you can spray the connections with that red terminal sealant (available at most auto parts stores) to protect the connection.



Rob

 

[Joe G.]

The manual is available at the Dodge dealer parts department. It is also available on-line but I don't have the URL handy. Maybe someone will chime in with it.



Normally I would suspect starter contacts are the problem, but you say the whole starter has been replaced. The '95 is quite a bit different than the 1st gen trucks for a lot of stuff. There is a heavy blue wire on the driver's side battery. It may have corroded inside and could be the cause of this problem. It also could be the ignition switch. There is a recall that may not have been done. Check with the Dodge dealer about it. The service department can look up the VIN and see if the recall has been done and/or if it applies to this truck. If it does apply it is a safety recall so there is no charge.

 

[kaffine krazed]

Does he have any alarm system on the truck? What happens if he jumps the starter relay terminals?

 

[mazdarotary]

Today we check for voltage at the battery,and the small wire that triggers the soleniod. The voltage at the starter is 12. 5V and the trigger wire has nothing until we turn the key and then we get 12. 3 there and a clicking sound and movement from some sort of solenoid that sits next to the brake master on the engine. After a few tries the engine will turn and start. We then tried bypassing the key buy running a hand held starter button from the + battery term down to the small wire termination on the starter and still just clicking and then after a few tries the engine will turn over and run just fine. This is a very intermiten problem and we have checked and cleaned all the connections on the battery and starter. The batteries are new and the starter was replaced. He never has any problem with the truck never starting at all but It may be heading that way. Help please he is talking about buying a toyota now:{ :{



Thanks

Chris

89 f-150 xlt soon to be replaced by a 92 d250 cc CTD

83 mazda RX-7 weekend racer and summer daily driver

in need of an engine now:{ :{

2001 Jayco kiwi 23B hybrid trailer

 

[Paychk]

This should help:



https://www.turbodieselregister.com...?s=&threadid=56967&highlight=starter+contacts



When you say new was that a Reman or a brand new? if Reman then the above may help.



edit for clarity

 

[Rhondasway]

This is a very timely thread for me. Starting a few days ago my 97 wouldn't turn over. I turn the key and nothing happens. It doesn't matter if I plug the truck in overnight. I've had the batteries both tested, as well as checking all connections. Everything is clean and dry, batteries are fairly new and test great, and even the starter is less than 2 years old.

I can turn the key up to 40 times, and occassionally I get a clicking, but not always. Once it engages, it turns over rapidly and starts right up. Battery dash indicator is normal.

I have tried "jumping it" with my charger, and it makes no difference. I let it run and "charge", warm up for some time, even driving it for maybe 15 minutes, and when I shut it off, same thing. If I drive it for an hour or more, I have no trouble starting it for the rest of the day.

Yesterday I waited until about 1 to start it, at which time it was 56 degrees outside, and it fired right up.

This morning I get nothing again. I have also trouble-shot and tested the neutral safety switch, as well as replaced the starter relay... If it were the contacts (I will order some to replace anyway), wouldn't I hear the solenoid engaging? I don't hear anything, and also don't have the disengage problem.

I have not bypassed the key yet (am not set up to do it, and by the time I get the truck rolling, most likely the test will be moot, correct? ).

I am and really don't want to bend over for the Dodge dealer just yet... Thanks for any help!

 

[rdrose]

contacts

found a guy that got me some contacts for $6. 00,

 

[BWilson]

You've probably already checked this but it sounds like a grounding issue. Check and/or replace the negatives going to the block. I would guess it's rare on these engines (because we have two) but I guess it could happen... .



Hope this helps.

 

[Rhondasway]

Thanks for the continuing input... I don't see the grounding problem, as it does not ever happen when the truck is thoroughly warmed up (would that change a ground? ).

This thread seems to be more about starters (I did order the kit and will replace the contacts and plunger), I think I need to focus more on the ignition. Anyone have any experience there? It's $92 for the switch from Dodge...

 

[Rhondasway]

fixed mine!

I don't know if Chris' brother in law got the problem fixed, but here's what I did: bought a new ignition switch from Dodge ($99)and installed it. It was that simple, and seems to have fixed the problem. The job only took about an hour, was very easy, and required only the following tools:

- 1/2" open end wrench for disconnecting battery,

- size T20 Torx (or "Star") wrench 3" length (replaceable bits in a drive won't work, too wide) for removing the steering column shroud,

- size T20 tamper-proof Torx for ignition screws (replaceable bits work fine for this part),

- grease

I don't know yet if a person can remove this switch and have it tested, which could save a bit of money. I opted to just change it as I have over 200,000 miles with lots of starts...

Hope this helps!

Oh, and Chris, the manuals for these trucks run about $120. Great Christmas present!

 

[klaybus]

Owners Manuals

Mazdarotary,

I found this DC site online that offers owners manuals & service manuals. Reasonable. Good Luck!



http://www.techauthority.daimlerchrysler.com/

 

[mazdarotary]

I just spoke with my brother in law whom just got the truck back from the stealer. He had it in for 4 recalls that were never done. They include ingnition swith wiring harness,some front spring problem,secondary hood latch,and one other thing i don't remember. He had them look into why it wouldn't stsrt. He thought maybe the ingnition wiring thing would fix it because if he used a hand held starter button wired from the battery to the starter it would start after a few tries. Well they did the recalls and it still didn't start. They told him they found the problem but he didn't tell me if they told him what it was. It turns out they just replaced the starter to the tune of $500+. Man the guys are worse than Mazda shops!!!That's why I never ever go to Mazda for work unless it's under warranty(my 83 hasn't been in a while). The thing is he replaced the starter with a rebuilt one from a auto parts store and that didn't work either. Could it be they soaked him for $500+ and just told him it was the starter ??Thanks for the input.







Chris

 

[Rhondasway]

do find out

It would be nice if he knew specifically what was wrong. A lot of folks may not care as long as it's fixed, but I think they need to have accountability. I usually ask to see the removed parts so I can inspect them. I'm guessing it wasn't the starter since he had already replaced it... If you find out, please let us know. Thanks!