I own a 2002 Dodge Caravan SE (3.3, V6). I swear there is something wrong with the starter. I went about the troubleshooting steps, as outlined in the service manual. The starter relay appears to be fine. The power going down to the solenoid is fine and the power going to the B+ connection of the starter appears fine. The last i tested the starter there was a smoke drifting out of it with an unusual smell. I figure it was time to remove the starter.

I removed the (2) bolts as seen on a couple YT videos but the starter assembly refuses to slide out. You can see from the photos below -- items (A), (B), (C) are the bolts or nut i removed.

(A) = the top of the bolt that connects to the B+ end of the starter. When unscrewing the nut it just ripped off a piece of the bolt. Apparently the nut is just fused in place and so taking a chunk of the stud with it.

(B) = this bolt was removed from the underside. It seemed to line up with the starter

(C) = this bolt was removed from the upper side. Note it has a nut on the end which was used to keep these extra wires in place. Dont know the purpose of those wires. Maybe they are grounds for the starter?

I would like to remove the starter but it is not budging. Besides the (2) bolts already removed is there another bolt i missed?! Can you direct me on how to successfully remove this starter? For the record i did remove the B+ connector and the solenoid connector from the starter.

The label on the side of the existing starter reads:

Chrysler
04686045AC
228000-9680
12v
DENSO

 

Do you know redneck rickem?

 

This starter has just the 2 bolts, and a stud between them. Have you tried tapping on the starter case? Perhaps it's corroded/rusted in place and needs to be freed up.

 

Ahh corroded or something eh. I will give it a tap. I just wasnt sure if there was a third bolt hiding somewhere. The service guide indicates 3 bolts in diagram. Will let u know.

 

The problem with those guides is that they sometimes don't point out differences in the various model years. Gen 4 goes from '01 to '07, but there is lots of variation for some systems in that time span. After '03 is when the 3 bolt starter arrived. They really should have put more time into those manuals because we always figure it's us making the mistake instead of them, and it's really frustrating for DIYers who don't do this stuff every day.

 

SUCCESS You were right and also about the 2 bolts!!

I was able to remove the Starter. Like you said about tapping it. I actually had to give it several wacks with the sledgehammer before it would start to wiggle a bit. I continued to give it taps but also tried using my hands to wiggle it back and forth. I gave up on the tapping and continued to wiggle it and OUT OF FRUSTRATION began really trying to twist it. I think it was that action that finally got it to pull out significantly.

Once i had the starter out i decided to attach the solenoid and B+ terminal to the battery. Oddly the starter worked fine. Hmmmm. I'll still get a replacement starter but will also be sure to clean both wire connectors before attaching them.

Thanks again!

 

ONE MORE THING...

Regarding re-installing the starter motor.....The Bell Housing Plate that rests between the starter and the engine mount:

1. Can i reuse the existing one or must i purchase a new one? Our vehicle is quite old and i will be purchasing a used starter to get me around for a few more months or so. I very much doubt it comes with its own plate.

2. The plate fell off once the starter was removed. I want to be sure i install it correctly. The one side is raised and the other side is completely flat. Which side faces the starter -- the raised side?

Thanks.

 

The spacer plate gets reused . The word UP is stamped on one side, and that side of the plate faces the starter. And the lip of the plate gets inserted between the block and the transaxle bellhousing. The starter working probably means it's the contacts that are worn, and the starter is fine. This is so common that there are contact replacement kits sold, which is a very easy DIY. Something for you to consider, if you have extra time to wait for a kit to be shipped and haven't bought the replacement starter yet.