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Okay, guys... was in the 30's today, but I threw down some cardboard and got to work. Lots of pics cause I like to document.... LOL
Can't be too safe....
Getting ready to pull the starter. The rear main seal leak keeps things coated in oil under there. Looks worse than it is. I don't usually have to add between changes but I do run a slight overfill that ends up being at the full point by the time another oil change comes around.
Anyway, got the bad boy pulled. Model number was not what I thought it was...
On the vise, somewhat cleaned up and about to dig in.
And just as I thought, here lies the problem. The starter solenoid is just one big relay with a plunger that makes contacts with those two copper contacts. When one contact wears down, the plunger only touches once side, so you get that single "click" when the plunger drops but does not complete the circuit.
This thing was really, really worn....right down to a razor edge. Worse than any I saw in the youtube videos.
Incredibly, I only got that "click" a few times. It kept starting even in the state that you see. These Nippondenso starters are tanks. Incredibly well designed.
Big difference from the new contacts....
Now you see how much deeper the wear on the left contact was, vs the right....
The plunger had basically no wear. You can tell only one side was really making contact. The other side was probably arcing.
Kinda how it would look with the plunger. If I was able to line things up like in the starter body, you'd see a gap on the left side.
New contacts are in and starter is cranking very well!
Miles at completion....
Had time for a hike this evening and snapped a few pics of the ATL skyline...
Hope this helps someone.
In case you wonder why I didn't just change the starter.... well, it wasn't because of the $$$. Yeah, the fix only cost $18, but really it's because I truly believe that after this repair, this starter with 338K on it, will still outlast the aftermarket junk you get from a parts store. Most of those starters only last a few years if you're lucky and I really didn't feel like doing this again. I had that experience with alternators and window regulators/motors. Heck the window motor failed after a month. Ended up trashing the parts store junk after they quickly failed and installed original Chrysler parts from the junkyard, which are working great.
Furthermore, if you think about it, the starter motor sees very few revolutions, compared to say.... an alternator. I suspect the motor brushes will still be in great condition. I'll let you know if this ever fails again but I suspect it will last as long as the truck.
Last edited by Dodgevity; Nov 21, 2022 at 09:00 AM.
Sure helps me so thanks! Well....it will likely help. Not sure yet if it's my problem. I'll watch the videos later.
I didn't have to read it again & again just to be able to follow along, unlike some posts.
Makes me think you might have done some business writing in the past.
It's still starting like a champ, but I've only put a few thousand miles on the truck since posting this thread.
Still runs like a bat out of hell but I generally only drive it on weekends to do stuff around the house. Just gave it a tune up, threw in a new battery (the old one died from sitting dormant outside too long in the summer heat) and installed a new water pump. Also popped the passenger valve cover off and replaced a few noisy lifters (which I replaced in 2020).... see what I mean about aftermarket parts?
Last edited by Dodgevity; Oct 24, 2023 at 02:43 AM.