Engine/Transmission (1998.5 - 2002) Truck Keeps Blowing Starter Fuses

[Midnite]

I'm having a starting problem with my 2000 truck. It's blowing starter fuses, and I can't seem to to find any places in the wiring where it may be shorting. I found the TSB calling for replacement of the 20 amp fuse with a 25 amp, and another calling for the same thing, but also replacing some of the wiring.



I replaced the 20 amp fuse with a 25 amp, but it's blowing that as well. This truck has about 95000 miles on it, and I'm betting the starter contacts are probably on their way out. But could marginal starter contacts cause the fuse to blow like this?



Thanks,

Mike

 

[Jerred]

sounds like that starter is starting to talk to you, no pun intended. mine on my 96 started to go (it would stay enganged after releasing the key, I thought it was a turbo that cocked a shaft!). I wish I had time to work on it, try new contacts and some of those parts available for rebuilds, but it happened literally days before moving to Alaska, so I just ran to CumminsWest and got a new starter. I'm sure mine had bearing issues and would have been toast anyway, but if your starter motor is turning off center, it might cause a big power spike from the monster starting amperage those things take when you first turn the key. but I'm no electrician, anyone out there with more knowledge of vehicle electrical systems? I know most parts stores can test your starter and narrow down the problem to either the motor (windings, brushes, stator) or the solenoid or a ground, might try that first.

 

[bmoeller]

I would have the starter tested. May need to be rebuilt.

 

[DTangstrom]

My 2000 did the same thing this summer. Most starters will tick when going bad, however I don't think the inadequate wiring and fuse will allow our model years to do this. I didn't waste the time or money on the TSB I just replaced the starter. My thought was up until 90,000 miles my truck started everytime I needed it to, so why change the wiring. 6,000 miles later with a new/rebuilt starter still going strong.

 

[Thomas]

The circuit shown in TSB 08-01-00 Rev A is the "after modification" circuit. I don't know if you have the Factory Service Manual or not, but my look at the starter circuit, both before and after the modification, hasn't shown me how worn starter contacts can blow fuse D.

Larry Buck at Foster Truck Accessories ( http://fostertruck.com/ ) may answer your question. He gets a lot of business from the TDR. Be aware that your model year 2000 Ram does not have the fuel shutoff solenoid mentioned on LarryB's site and is wired differently than the earlier second-generation Ram circuit shown there.

Attached is a picture of the worn contact removed from the starter of my model year 2000 Ram five days ago. I imagine the wear is typical of most six-plus year old Rams. I figured the contacts would be easier to replace in my garage than along the road.

Let us know what you find out.

 

[hpyman123]

My 01 started doing the same thing. I wound up just getting another starter. My local NAPA guy had a starter in stock with a lifetime warranty for about 80. 00. Has been fine ever since.

 

[Midnite]

Well, I wouldn't have thought that worn solenoid contacts could cause the fuse to blow, but the contacts were certainly the problem. The one that was worn is a spitting image of the one Thomas posted a picture of. Many, many thanks to Bob Robertson, who let me use the solenoid rebuild kit he had from LarryB, and also to JR2 for his help.



Thanks for the replies,

Mike

 

[JR2]

And thanks Mike for the ride home after my problems.....

 

[Midnite]

Anytime John! I hope it's nothing more serious than a cooler line that popped loose.



Mike

 

[webelect]

Thanks for the information. Ill get back to all of you what I find. Might take it to get tested.



Thanks

 

[WatsonJ]

There is another TSB

mine did the same one night at midnight in an airport parking lot.



there is a TSB that involves adding a jumper to the fuse box under the hood.

it bypasses the existing circuit. Dodge sells the kit. was about 65 bucks

4-5 years ago. Takes 10-15 minutes to install. no problems after that,



except for the starter contact issue that came up a year later. I replaced those with the heavy duties described in earlier posts.



sorry I dont have the TSB number with me. it's at home filed in the toolbox.