Been having starter issues. Turn key, clicks and after some tries could get it going. Got worse as time went on to where almost could not start. Assuming most likely solenoid contacts worn.

Purchased new AC Delco Gold 337 1100. Since battery terminals were not in good shape, I first replaced them and started the truck before moving onto the starter. Was only one click and second try started right unlike last attempts for some time.

Battery is not that old but had Autozone do an alternator/battery/starter check after clicking problem started and they said all was good... another reason I figured it was just the contacts/solenoid or starter generally.

I then removed the bolts on the starter to drop it down and noticed immediately the solenoid wire had been spliced at two locations using crimp connectors and a bit of the wire was showing on one. I am original owner and have no idea who did that or why. The clicking problem seemed to be exacerbated by moisture at times, rain or early in the day and then considered the wire being exposed was allowing it to get wet or moist. Old denso starter had a plug connector which I cut off with the one crimp that had leaving the other as the wire would have been too short. I slid a shrink wrap over the remaining crimp connection/partly exposed wire, and added an O ring connector to the end.. I also sanded the larger o ring and put a bit of dielectric grease on everything I installed the new starter and then got nothing when I turned the key. I called AC Delco and they seemed to think the starter might be defective but I am not sure. It was mail ordered and want to make sure it is bad before sending it out. I took it out to first check connections and then test. So I also pulled the battery to bench test the old and new starters tomorrow which I can do. I put a charger on the battery as it had been used starting without running and windows up and down and it only took a short time to fully charge (charger has no meter).

If the new starter is good, I want to test the lines going to the starter which is where I get stupid....anything electrical. It seems to be a brain fart or block for me. I read a bunch of threads here and this electrical stuff just makes my brain freeze. Assuming the new starter passes the test (and the old one for that matter).... I also ordered the solenoid rebuild and will open up the old starter and check the brushes and solenoid to see if it is the solenoid and can be repaired which I will do if the brushes are good.

My questions:

1. Do I need something that can read not the power output or volts going through them to make sure it is sufficient power getting to the starter due to the crimps? Or is a light test sufficient which I think not. If a multiester is needed, any recommendations for one at a reasonable cost would be appreciated.

2. If I need to know how much power is going through, how do I find what the correct power going through each wire (the starter and the solenoid wires) should be to compare?

3. Since there are two wires coming to the starter, do I test both of them separately and should it be in the start position? The solenoid wire is small and black. The starter wire is larger and red in this situation. But I am assuming both are supplying power since you have to jump them to bench test.

4. Is the following correct?
(a) The larger starter wire comes directly from the battery.
(b) The smaller solenoid wire originates from the ignition switch to the fuse box under the hood/to the starter relay (which i switched out with the horn relay to make sure was good per suggestions here) and then goes from there directly to the solenoid?
(c) That smaller solenoid wire is 12 gauge.

My apologies on this and it is high time I start to learn electrical and no time like the present. I have attached some pics of the wires for clarity.

 

I have a '96 Ram 2500 4x4 with a 5.9 magnum engine. Since the truck was over 20+ years old at the time (and had been subjected to a fair amount of road salt, as the truck was a former snow plow truck), I ended up replacing the battery & starter cable with an new OEM MOPAR part, as my cables that connected to my starter had gotten old, frayed and corroded. Sometimes, the corrosion gets into the cable in areas that you can't see and causes the cable to not be able to carry the electrical load needed to properly operate the starter. I believe the OEM positive cable attaches to the battery and also connects within the underhood electrical box on the driver's side fender and then onto the starter.

 

You have a big red cable that goes directly from the battery to the starter. I can't remember if there are two or one wire in the plug.

 

I purchased a multimeter....long overdue. Battery is good and holding charge fine. Bench tested the old starter which was defective as I knew and after examination decided not to try and rebuild for a number of reasons including it was going to be more than just the solenoid. I bench tested the new starter and it was in fact defective...as in nothing. I used the multi meter to ensure that the wires starter were delivering juice and registering I had pulled out the battery before getting the multimeter. Replacement starter due Sunday. I am going to put battery back in and test the starter wires. I believe the solenoid wire which I was concerned about should read 9 volts in the run position. Can anyone verify that please? If all is good will pull it out and test replacement starter before installing which I would recommend after what i have been through.

I have another question which is sort of embarrassing. When jumping due to a dead battery, I always attached the red to the dead battery and then to the live one. Then attach the black cable to the live battery and this is where I think I have been doing it wrong. I always attached it to the negative terminal on the dead battery. I read you should not and should attach it to a ground on the vehicle. What would that be? I also read that if you are getting a spark when attaching to the negative to the dead vehicle, that means there is a short somewhere. Is that correct information?

I have had another electrical issue I am sure is related to when someone removed the car alarm. After that, what would happen is if the air or heat was running and I honked the horn, the horn would make sound and immediately cut out and the heat/ac would stop working. It would blow the horn fuse on the fuse block on the engine. This went on for years and I would simply replace the fuse. Any advice to look into that would be appreciated.

My very last thing here is this.... I got shocked non-vehicle related rather badly a number of years ago that left me overly concerned about all things electrical. Old metal cased hedge trimmer and cut the chord, the trimmer went live and oddly was not able to immediately release the trimmer and was shaking before I finally released it. I was buzzed for a long time after and sorta freaked out over electricty. I have done wiring in my home but would never touch the box and hire someone for that. After getting the multi-tester and playing around I am feeling more confident and willing to learn. What is there out there that I can buy with electrical diagrams and troubleshooting and perhaps test recommendations. I saw something Haynes mentioned... is that the best one or is there another one and does anyone have any links? And are there any good threads anyone can point me to get me started? Or sticky notes? Seems most of what I have found are threads related to specific issues.

You guys rock and have helped me many times and is much appreciated. Will definitely follow up on this starter issue. And much thanks in advance.

 

You should only see voltage on the solenoid wire when the key is in the start position. Minimum of 9 volts to activate the solenoid.

See sparks when you hook up the battery is normal.

You can download a factory service manual for your truck from here. It is specific to your truck, and is FAR superior to any other publication out there.

 

Thanks for the assistance HeyYou. I installed the replacement starter and it is working like a champ.

 

Awesome.