I have a 2002 GC Sport with a cold start CLICK. Working the key to and fro will get her up and the rest of the day its fine but this AM it was stubborn so here we go.

• Earlier on I swapped out the fuse box solenoid but it was not a cure.
• I have checked all the connections I can see and they are all tight.

I have searched and read here about other year models having two wires on the top bolt. Is this the case with my 2002?

Is there something else I need to look into before dropping $80.00 on a starter?

Thanks

 

Those two wires are for ground. You may just have a bad bendex on the starter, which means it time to replace the starter sorry. Once the starter is out. Inspect the teeth on the flex plate by turning the engine by hand, You be looking for some damage teeth.

 

The problem is the contact in the starter solenoid. I say this with 99% certainty. read this (yes it says toyota but they use the exact same starter design) http://www.4crawler.com/4x4/CheapTricks/Starter.shtml

total cost to fix contact is under $10. I buy the parts from my Toyota dealer for $5.88 Chrysler dealers don't carry the parts and most auto parts stores don't seem to either.

 

Interesting!

 

when the problem occurs sometimes it will take numerous attempts before you get engagement... eventually no amount of attempts will allow the starter to engage.

 

Do you know which part number in the article applies to my 2002 GC starter?

 

first, take out your starter, remove cover with 3 little bolts and inspect contacts. if I'm right and they are bad, "TRY" going to an autoparts store with the parts in your hand then you can make sure you have the correct part. I am not an autoparts store, I don't memorize part numbers. All I do is bring a part with me to an appropriate store and verify I get the correct replacement.

It's been 8 years since I had to find the parts to replace these. I spent hours trying to find the parts, not one national box store had them (napa, carquest, autozone, advance, oreilly, bumper to bumper, etc.) So, in desperation, I went to chrysler dealer and NO LUCK. however the chrysler dealer was also a Toyota dealer and the parts person laughed then said "how about some Toyota parts in your Chrysler?" She pulled out a box full of contacts of different configurations. found what I needed and $5.88 later I was in business. Since that event, I found a mail order automotive shop supply company that carries them for under $1.50 each, so I bought a bulk of them. anyway, I'll leave the leg work to you on allocating the part.

In review, verify this is the problem. Try your local autoparts store to see if they can attain such parts or try your local Toyota dealer.

Good luck and have fun. Be sure to DISCONNECT the negative battery cable at the battery prior to any work on the starter!!!!!!!!!!!!!

 

Thanks,

I just ordered the multi pack from the 4Crawler site. I hope he is still active.

I'll report back on how I did and which ones are for my 2002 in the event some poor soul does a search.

 

The Starter Removal, Contact Replacement and Installation was a great success! Thanks guys! $10.00 Vs. $80.00. Mercy Louella!
Thanks Tizzy 1 for the manual picture info.
Thanks 22mopar22 http://www.4crawler.com for the fabulous Webb site instructions and the fast order precessing of the contacts I ordered.

My 2002 Grand Caravan Sport used the A & B contacts in the set ordered from 4crawler. I think the multiple part numbers are all the same part but for different vehicles so if one is out of stock ask for the other. Or order from 4Crawler.
A: Toyota p/n 28226-72010, 28226-72080, 28226-74040.
B: Toyota p/n 28226-72040, 28226-22050.

I pulled the starter and changed the contacts and put her back in and she is good to go.

Starter Change notes for a 2002 Grand Caravan:

As per usual disconnect the negative battery wire.
Disconnect the wires from the starter.

• Do the Top bolt 1st so the starter can walk out when you do the bottom bolt. The top starter bolt can be done from above.
• There are two ground wires on the top starter bolt. A medium 3/8 drive extension and deep well 13mm removes that nut.
• Change to a 15mm and remove the top bolt.
• The bottom bolt is accessed from the bottom. I used a flex-head long handled 3/8 drive ratchet (on top and bottom bolts) and a regular 15mm socket to remove it.
• When you are backing out the bottom bolt the ratchet will move out and hit something so you need to push the starter out as you loosen the bolt.
• I cleaned the starter with Simple Green and removed the solenoid cover.
• I did one contact at a time.
• The battery wire contact is simple and take care on both to keep track of what you are doing so you can reverse it. When you tighten the contacts make sure you do not let them rotate to an out of level position. There was a paper shim or gasket on my battery wire side.
• The other side has a very small wire coming out of the motor terminating at the bolt so take care not to break it. If that wire breaks you are headed to the parts store with $80.00.
• I used a very small tack hammer to gently rap on it to loosen everything off the bolt so I could easily pull it out through spade connector with minimal flexing of the wire.
• I used a very fine stiff wire brush to clean the plunger disc. It was pitted and worn but will last another 100k.
• Assembly. The metal shim that goes between the starter and the motor will give you a fit so be patient and slide it all in taking care to know you have it all lined up. You will need a light so you can peek in and see the dowel pin go into the hole and keep an eye on the shim plate.
• Work the lower bolt in and get it a little tighter than hand tight and move to the top. Tighten the top but not with the wires yet.
• Then tighten the bottom and check the top again and re-fasten the wires.
• Connect the battery and Test.

The old contacts pictured below with the Battery side being the most worn.

 

Your quite welcome.

amazing how I steered you to the exact problem, clearly explained the problem and how to correct, found you step by step pictures, and saved you a ton of money.... I like beer