Frequently Asked Questions about our starters and parts.
Q: How do bad starter contacts cause the engine to keep running when I turn off the key?
Click this for >>Dodge Ram wiring diagram << showing starter wiring.
A: The fuel shutoff solenoid is actually two solenoids in one. One coil is very strong to pull the linkage open when you hit the starter to let fuel flow. This first coil produces lots of heat and is intended for short use. The second coil is smaller and has just enough power to hold the solenoid open for running. It does not build up heat like the stronger coil.
The stronger coil is wired in with the starter so when you hit the starter the fuel solenoid opens and the engine starts. When you let the key return to the run position only the second smaller coil is needed to hold the solenoid open.
When the worn starter contacts hang and stick closed the stronger first coil stays energized along with the starter. This causes heat buildup after a short time and can actually catch fire if the battery isn't disconnected quickly.
Stock contacts usually last around 100K miles and are commonly the first problem to show up with these starters. Up until recently the only repair option was to replace the starter and you're good for another 100k. Now that Super Contacts are available we have a cheap and better fix that's better than stock. Most starters I have seen look to be quite usable upon tear down and contact replacement.
Q:
If I just replace the contacts will this eliminate the Fuel shutoff relay
burning up possibility??
Also- I assume the oversized contacts will make the new starter last longer??
A:
Yes, replacing the contacts will most likely prevent the starter from sticking and burning
up the fuel shut-off. But to make absolutely sure you should install a
SolenoidSaver diode.
Q. Why did just one contact wear so badly and the other hardly looked worn?
A. Simply put, direct current (DC) travels in one direction causing one side of an arc to burn more. so the when the power travels from the first contact to the plunger the plunger may burn but over a larger area. As the plunger has a much larger contact area the burning is less noticeable. When the power travels from the plunger to the second contact, the second contact gets burned. At least this is how I understand it. Hope this helps.
Q. Sometimes I need to turn the key three or four times before the engine will crank. Could this problem be worn contacts?
A. Most definitely. The old burned and worn away contacts have a hard time connecting because of a very poor contact surface. Also misalignment due to wear makes contact even more difficult. Without good contact power cannot flow from the battery to the starter.
Q. Can worn batteries cause contact wear?
A. Yes! In all but the earliest Cummins powered Dodge trucks a double battery system is used. This system works great when the batteries are in good working order. Unfortunately this system will also mask battery problems because one good battery will mask problems with the other bad battery. Low cranking amps can cause excess arcing in the solenoid contacts resulting in burned contacts. Check your batteries often!
Q: What size wrench do the starter bolts take? Is it a Torx bit?
A: It is a 10mm, 12 point head. A 12 point box end wrench works best.