Contents Section: Starter All sections

Starting System Dodge Cab & Chassis R3500

Starter 11 illustrations ~3874 words

DESCRIPTION

Note. For models not covered in this article, see STARTERS - AVENGER, SEBRING COUPE & TALON article.

Bosch, Melco and Mitsubishi starters use a planetary gear train that transmits power from starter motor to pinion shaft. Six permanent magnets (Bosch and Melco starters) or 4 permanent magnets (Mitsubishi starters) are used, eliminating potential field wire-to-frame short circuits.

Nippondenso starter is a 4-field, 4-brush, 12-volt motor with a solenoid mounted within the housing. The unit has a 2-to-1 reduction gear set in a die cast aluminum housing. Starter has serviceable gear and clutch assembly only. If starter solenoid fails, entire starter motor must be replaced.

All models use a starter relay in starter circuit between the battery and starter solenoid terminal. Automatic Transmission (A/T) equipped vehicles use a Park/Neutral Position (PNP) switch or a Transmission Range (TR) sensor to provide ground path for the starter relay. Manual Transmission (M/T) equipped vehicles use a clutch pedal position switch to provide battery voltage from ignition switch to the starter relay. See WIRING DIAGRAMS .

ModelType
Breeze & Stratus 2.0LBosch
Cirrus, Sebring Convertible & Stratus
2.4LNippondenso
2.5LMelco
Concorde, Intrepid, LHS & 300M
2.7LMelco
3.3L & 3.5LNippondenso
NeonBosch

STARTER APPLICATIONS - CARS

ModelType
Caravan, Town & Country, & VoyagerNippondenso
Dakota & Durango
2.5LMitsubishi
3.9L & 5.2LNippondenso
Ram Pickup, Ram Van & Ram WagonNippondenso

STARTER APPLICATIONS - TRUCKS

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING

CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

DISABLING/ENABLING IGNITION & FUEL SYSTEMS

WARNINGTo prevent engine from starting while performing tests, always disable ignition and fuel systems.

Disabling Ignition & Fuel Systems

Remove Automatic Shutdown Relay (ASD) located in Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment. On 5.9L diesel engines, also disconnect fuel shutdown solenoid connector. Solenoid is located behind upper intake manifold. See appropriate SYSTEM & COMPONENT TESTING article in ENGINE PERFORMANCE.

Enabling Ignition & Fuel Systems

When testing and/or repairs have been completed, verify battery condition. Recharge battery as necessary, after starter tests have been completed. Disconnect all test equipment. Install ASD relay. On 5.9L diesel engines, reconnect fuel shutdown relay connector. On all models, start engine several times to verify malfunction has been corrected.

CRANKING TEST

Note. Ensure engine is at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw.

  1. Using a battery load tester, connect positive and negative leads to battery. Connect inductive ammeter pick-up to positive battery cable. Disable ignition and fuel systems. See «DISABLING/ENABLING IGNITION & FUEL SYSTEMS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__disablingenabling-ignition-fuel-systems) .
  2. Ensure all lights and accessories are off. Place A/T in Park position or M/T in Neutral position. Apply parking brake. Crank engine and observe voltmeter reading. If voltage is more than 9.6 volts and cranking amperage draw is more than specified amps, proceed to «CIRCUIT RESISTANCE TESTS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__circuit-resistance-tests) . See «STARTER SPECIFICATIONS - CARS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system) or «STARTER SPECIFICATIONS - TRUCKS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system) .
  3. If voltage is 12.5 volts or more and cranking amperage draw is less than specified, check starter circuit components in the following order: starter solenoid, starter relay, starter relay circuit, park/neutral position switch or transmission range sensor (A/T), clutch pedal position switch (M/T), ignition switch, wiring harness and connections.

CIRCUIT RESISTANCE TESTS

Note. If excessive resistance is not found in circuits being tested, remove starter and proceed to BENCH TESTING .

Battery Connection Resistance Test

  1. Disable vehicle ignition and fuel systems. See «DISABLING/ENABLING IGNITION & FUEL SYSTEMS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__disablingenabling-ignition-fuel-systems) . A voltmeter accurate to one tenth of a volt will be needed for the following tests.
  2. Connect voltmeter positive lead to negative battery cable clamp. Connect voltmeter negative lead to negative battery post. Crank engine and observe voltmeter reading. If voltage is detected, repair poor contact between cable clamp and post. Perform same procedure to positive battery post and cable clamp.

Ground Connection Resistance Test

Connect voltmeter negative lead to negative battery post. Connect voltmeter positive lead to engine block, near negative battery cable grounding point. Crank engine and observe voltmeter reading. If voltmeter reading indicates more than 0.2 volt, repair poor ground connection or replace ground cable.

Starter Ground Connection Resistance Test

Connect voltmeter negative lead to negative battery post. Connect voltmeter positive lead to starter housing. Crank engine and observe voltmeter reading. If voltmeter reading indicates more than 0.2 volt, repair poor starter-to-ground connection.

Positive Battery Cable Resistance Test

  1. Remove starter heat shield (if equipped) to gain access to starter solenoid connections. Connect voltmeter negative lead to starter solenoid battery terminal and voltmeter positive lead to positive battery post.
  2. Crank engine and observe voltmeter reading. If voltage reads more than 0.2 volt, correct poor connection between battery cable and starter solenoid or replace positive battery cable.

SOLENOID CIRCUIT TEST

Note. Perform SOLENOID CIRCUIT TEST before testing starter relay and starter relay circuit. Ensure A/T is in Park position or M/T is in Neutral position and parking brake is applied.

  1. Disable vehicle ignition and fuel systems. See «DISABLING/ENABLING IGNITION & FUEL SYSTEMS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__disablingenabling-ignition-fuel-systems).
  2. Ensure battery is fully charged. Ensure solenoid connections are not loose or corroded. Remove starter relay from Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment.
  3. Connect a remote starter switch or jumper wire between starter relay socket terminal No. 87 and positive battery post. (Scheme 1)or (Scheme 2). If engine cranks, solenoid and starter are good. Go to «STARTER RELAY TEST»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__starter-relay-test).
  4. If engine fails to crank, or if solenoid chatters, check wiring and connectors from starter relay socket to starter solenoid terminal. Repair any loose or corroded connections. If engine still fails to crank, remove starter and proceed to «SOLENOID TEST»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system) under BENCH TESTING.

STARTER RELAY TEST

Note. Perform SOLENOID CIRCUIT TEST before testing starter relay.

Remove starter relay from Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment. Connect 12-volt power source to starter relay terminal No. 86 and ground terminal No. 85. (Scheme 1)or (Scheme 2). Using ohmmeter, check continuity across starter relay terminals No. 30 and 87. If continuity is not present, replace starter relay.

Scheme 1

Scheme 1: STARTER RELAY TEST

Scheme 2

Scheme 2

STARTER RELAY CIRCUIT TEST

Note. Perform STARTER RELAY TEST before testing starter relay circuit.

  1. Ensure battery is fully charged. Remove starter relay from Power Distribution Center (PDC). Refer to PDC cover for proper relay location. PDC is located in engine compartment.
  2. Connect a jumper wire between starter relay socket terminal No. 30 and terminal No. 87. (Scheme 1)or (Scheme 2). If engine does not crank, go to «SOLENOID TEST»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__solenoid-test) under BENCH TESTING. If engine cranks, go to next step.
  3. Turn ignition on. Check voltage between ground and starter relay socket terminal No. 30. If battery voltage is not present, repair open in circuit between starter relay socket and battery. If battery voltage is present, go to next step.
  4. Check voltage between ground and starter relay socket terminal No. 86 with ignition switch in START position and clutch pedal depressed (if equipped with M/T). If battery voltage is present, circuit is okay. Go to step 6 if equipped with M/T or step 7 if equipped with A/T. If battery voltage is not present, repair open in circuit between ignition switch and starter relay socket (A/T) or go to next step (M/T).
  5. Unplug wiring connector from clutch position switch mounted on clutch pedal bracket. Connect jumper wire between clutch position switch connector terminals. Recheck for voltage at starter relay socket terminal No. 86 with ignition switch in START position. If battery voltage is present, check clutch position switch adjustment (if applicable). Adjust switch as necessary. If switch adjustment is okay, check clutch position switch. See «CLUTCH POSITION SWITCH TEST»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__clutch-position-switch-test). If battery voltage is not present, repair wiring between ignition switch and starter relay socket as necessary.
  6. On M/T models, connect voltmeter negative lead to starter relay socket terminal No. 85 and positive lead to terminal No. 86. Turn ignition switch to START position and depress clutch pedal. If battery voltage is present, starter relay socket ground circuit is good. Replace faulty starter relay. If battery voltage is not present, repair ground wire circuit.
  7. On A/T models, connect voltmeter negative lead to starter relay socket terminal No. 85 and positive lead to terminal No. 86. Ensure transmission gear selector is in Park or Neutral position. Ground circuit runs through Park/Neutral Position (PNP) switch or Transmission Range (TR) sensor on transmission. Turn ignition switch to START position. If battery voltage is present, starter relay socket ground circuit is good. Replace faulty starter relay.
  8. If battery voltage is not present, check PNP switch or TR sensor for loose or damaged connections. Also, check ground to PNP switch or TR sensor. Repair as necessary. If connections and ground are okay, check PNP switch or TR sensor. See «PARK/NEUTRAL POSITION (PNP) SWITCH & TRANSMISSION RANGE (TR) SENSOR TEST»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__parkneutral-position-pnp-switch-transmission).

PARK/NEUTRAL POSITION (PNP) SWITCH & TRANSMISSION RANGE (TR) SENSOR TEST

Note. Transmission Range (TR) sensor may be also known as Park/Neutral Position (PNP) switch or Park/Neutral switch.

Note. The following test is for Caravan, Ram Van, Ram Wagon and Voyager with 3-speed transmission. All other models are equipped with a Transmission Range (TR) sensor. If TR sensor or sensor circuit is defective, see appropriate NTC test in appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

  1. Place gear selector in Park. Disconnect negative battery cable. Raise and support vehicle. Disconnect PNP switch connector. Using an ohmmeter, check for continuity between ground and PNP switch center terminal. If continuity exists, go to next step. If continuity does not exist, replace PNP switch.
  2. Place gear selector in Reverse. Check for continuity between ground and PNP switch center terminal. If continuity exists, PNP switch is okay. If continuity does not exist, replace PNP switch.

CLUTCH POSITION SWITCH TEST

Disconnect negative battery cable. Disconnect clutch position switch connector. Using an ohmmeter, check for continuity between clutch position switch terminals. With clutch pedal released, continuity should not exist. With clutch pedal depressed, continuity should exist. Replace clutch position switch if continuity is not as specified.

IGNITION SWITCH TEST

Note. For ignition switch testing procedures, see appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT.

SOLENOID TEST

  1. With starter removed from vehicle, remove starter motor field coil wire from solenoid field coil terminal. Using an ohmmeter, check for continuity between solenoid terminal and field coil terminal of starter solenoid. Continuity should exist.
  2. Check for continuity between solenoid terminal and solenoid housing. Continuity should exist. If continuity is not present in either test, replace starter and solenoid as an assembly.

Removal (2.0L Neon)

  1. Disconnect negative battery cable.
  2. Raise vehicle.
  3. On vehicles with A/C: Using a floor jack or jack stand, support the engine and transmission assembly so they will not rotate. Remove the front engine mount bolt from the insulator and front crossmember mounting bracket. Lower the front of the engine, rotate the engine forward, allowing easier removal of starter motor.
  4. For easier servicing, do not remove the wiring from the starter at this time.
  5. Remove 2 bolts attaching starter to transmission housing.
  6. Remove starter/starter solenoid assembly from transmission housing. Position the starter to gain access to the wiring connectors.
  7. Remove the battery positive cable nut and remove the battery positive and generator output wire from the starter.
  8. Disconnect push-on solenoid connector. Pull back on slide and push down on rear tab to release lock.
  9. Position the starter vertically such that the pinion end faces downward.
  10. Remove the starter through the bottom of the vehicle. Move aside A/C plumbing as necessary.

Removal (2.0L Cirrus, Sebring & Stratus With A/T & 2.4L)

  1. Disconnect battery negative cable from remote negative terminal on shock tower.
  2. Remove air cleaner resonator.
  3. Remove three Transmission Control Module (TCM) mounting screws. Move TCM to provide access to top starter mounting bolt. DO NOT disconnect TCM wiring.
  4. Remove top bolt attaching starter to transmission housing.
  5. Raise vehicle.
  6. Remove battery positive cable nut from starter and remove cable.
  7. Disconnect push on solenoid connector. Unlock the red locking tab and compress lock to release the connector (2.0L only).
  8. Remove the bottom bolt attaching starter to transmission housing.
  9. Remove starter from vehicle.

Removal & Installation (2.0L Cirrus, Sebring & Stratus With M/T)

  1. Disconnect the remote battery negative cable from the terminal on shock tower.
  2. Remove air cleaner resonator.
  3. Remove the battery positive cable nut from starter. Remove battery positive cable and generator output wire from starter.
  4. Disconnect push on solenoid connector. Unlock the red locking tab and compress lock to release the connector.
  5. Remove two bolts attaching starter to transmission housing and remove starter from vehicle.

For installation, reverse the removal procedures. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid.

Removal (2.4L Except Stratus & 3.0L)

  1. Release hood latch and open hood.
  2. Disconnect battery negative cable.
  3. Hoist and support vehicle on safety stands.
  4. Remove nut holding solenoid wire to terminal.
  5. Remove nut holding B+ wire to terminal.
  6. Disconnect solenoid and B+ wires from starter terminals.
  7. Remove bolts holding starter to transaxle bellhousing.
  8. Remove starter.

Scheme 3

Scheme 3: Removal (2.5L Dakota, 3.9L, 5.2L & 5.9L Gasoline)
  1. Disconnect and isolate the battery negative cable.
  2. Raise and support the vehicle.
  3. Remove the nut and lock washer securing the starter motor to the mounting stud on the transmission torque converter housing. (Scheme 3)
  4. While supporting the starter motor with one hand, use the other hand to remove the upper mounting screw from the starter motor.
  5. Slide the automatic transmission cooler tube bracket forward on the tubes far enough for the starter motor mounting flange to be removed from the lower mounting stud.
  6. Move the starter motor towards the front of the vehicle far enough for the nose of the starter pinion housing to clear the transmission torque converter housing. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  7. Tilt the nose downwards and lower the starter motor far enough to access and remove the nut that secures the battery positive cable connector eyelet to the solenoid battery terminal stud. (Scheme 3) Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  8. Remove the battery positive cable connector eyelet from the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  9. Disconnect the battery positive cable wire harness connector from the solenoid terminal connector receptacle. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  10. Remove the starter motor from the engine compartment.

Removal & Installation (2.5L Except Dakota)

  1. Disconnect battery negative cable from remote negative terminal on shock tower.
  2. Raise vehicle.
  3. Remove oil filter.
  4. Remove battery positive cable nut from starter and remove cable.
  5. Disconnect push on solenoid connector.
  6. Remove three bolts attaching starter to transmission housing and remove starter from vehicle.

For installation, reverse the removal procedures. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid

Removal & Installation (2.7L)

  1. Disconnect battery negative remote cable from remote ground.
  2. Raise vehicle.
  3. Remove 2 wiring harness connectors. One for battery feed, and one posi-lock connector.
  4. Remove 2 bolts and one nut to starter heat shield.
  5. Remove 3 starter attaching bolts from engine/transaxle.
  6. Remove starter assembly from transmission housing.
  7. Rotate starter solenoid toward engine block and slide rear of starter motor out between catalyst and engine mount.
  8. Remove the starter from vehicle.
  9. To install, reverse the removal procedures. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid.

Removal & Installation (3.2L & 3.5L)

  1. Disconnect battery negative remote cable from remote ground post.
  2. Raise vehicle.
  3. Remove 3 bolts attaching starter to engine.
  4. Remove battery positive feed wire from starter.
  5. Remove starter solenoid assembly from transmission housing. Position the starter to gain access to the posi-lock wiring connector.
  6. Position jack stand beneath engine and slightly lift to relieve pressure from left engine mount.
  7. Remove 3 left engine mount mounting bolts from engine block.
  8. Jack engine up slightly to give more room to maneuver starter assembly.
  9. Slide rear of starter motor out between catalyst and engine mount.
  10. Disconnect posi-lock starter solenoid connector.
  11. Remove the starter from vehicle.
  12. To install, reverse the removal procedures. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid. Reconnect posi-lock connector right after starter is placed into position.

Removal (3.3L & 3.8L)

  1. Release hood latch and open hood.
  2. Disconnect and isolate the battery negative cable.
  3. Hoist and support vehicle on safety stands.
  4. Remove nut holding B+ terminal to starter solenoid.
  5. Disconnect solenoid connector from starter.
  6. Remove bolts holding starter to transaxle bellhousing.
  7. Remove starter from bellhousing.
  8. Separate starter spacer from transaxle bellhousing.

Removal (5.9L Diesel)

  1. Disconnect and isolate the negative cables of both batteries.
  2. Raise and support the vehicle.
  3. Pull back the protective rubber boot from the solenoid battery terminal far enough to access and remove the nut that secures the battery positive cable wire harness connector eyelet to the solenoid battery terminal stud.
  4. Remove the nut that secures the battery positive cable wire harness solenoid connector eyelet to the solenoid terminal st.
  5. Remove the battery positive cable wire harness connector eyelets from the solenoid terminal studs.
  6. While supporting the starter motor with one hand, use the other hand to remove the three screws that secure the starter motor to the flywheel housing.
  7. Remove the starter motor from the engine compartment.

Removal (8.0L)

  1. Disconnect and isolate the battery negative cable.
  2. Raise and support the vehicle.
  3. Remove the nut that secures the battery positive cable wire harness connector eyelet to the solenoid battery terminal stud.
  4. Remove the battery positive cable connector eyelet from the solenoid battery terminal stud.
  5. Disconnect the battery positive cable wire harness connector from the solenoid terminal connector receptacle.
  6. While supporting the starter motor with one hand, use the other hand to remove the two screws that secure the starter motor to the engine.
  7. Remove the starter motor from the engine compartment.

Installation (2.0L Neon)

  1. Clean corrosion/dirt from the cable and wire terminals before installing wiring to the solenoid.
  2. Connect the battery positive and generator output wire to the starter solenoid post.
  3. Connect the push-on until fully engaged.
  4. Position the starter face into transmission housing. Support starter in pilot and start the top bolt.
  5. Attach ground cable to lower mounting bolt and start bolt.
  6. Ensure the proper starter alignment before tightening the starter mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__torque-specifications) .
  7. On vehicles with A/C: Using a floor jack or jack stand, raise the engine and transmission assembly to original position. Install the front engine mount bolt through the insulator and front crossmember mounting bracket. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/cab-chassis-r3500/1996-2002/remont/starter/#starting-system__torque-specifications) .
  8. Lower vehicle and connect negative battery cable.

Installation (2.0L Cirrus, Sebring & Stratus With A/T & 2.4L)

  1. With vehicle is raised, set starter face into transmission housing.
  2. Lower vehicle.
  3. Install top starter mounting bolt but do not tighten.
  4. Raise vehicle.
  5. Install bottom starter mounting bolt and tighten to 54 N.m (40 ft. lbs.) torque.
  6. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid.
  7. Connect battery positive cable to solenoid post.
  8. Connect the push-on solenoid connector.
  9. Lower vehicle.
  10. Tighten top starter bolt to 54 N.m (40 ft. lbs.) torque.
  11. Install TCM and the mounting screws.
  12. Install air cleaner resonator.
  13. Connect battery remote cable to the remote terminal.

Installation (2.4L Except Stratus & 3.0L)

  1. Place starter in position on vehicle.
  2. Install bolts to hold starter to transaxle bellhousing.
  3. Place solenoid and B+ wires in position on starter terminals.
  4. Install nut to hold B+ wire to terminal.
  5. Install nut to hold solenoid wire to terminal.
  6. Lower vehicle.
  7. Connect battery negative cable.
  8. Verify starter operation.

Installation (2.5L Dakota, 3.9L, 5.2L & 5.9L Gasoline)

  1. Position the starter motor in the engine compartment.
  2. Reconnect the battery positive cable wire harness connector to the solenoid terminal connector receptacle. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  3. Install the battery positive cable connector eyelet over the solenoid battery terminal stud. Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  4. Install and tighten the nut that secures the battery positive cable connector eyelet to the solenoid battery terminal stud. Tighten the nut to 13.6 N.m (120 in. lbs.) Always support the starter motor during this process, do not let the starter motor hang from the wire harness.
  5. Position the starter motor to the front of the manual transmission clutch housing or the automatic transmission torque converter housing.
  6. If the vehicle is equipped with an automatic transmission, , slide the automatic transmission cooler tube bracket rearward on the tubes and into position over the upper mounting hole in the starter motor mounting flange.
  7. Loosely install the screw that secures the upper starter motor mounting flange to the transmission torque converter housing.
  8. Install the lock washer and loosely install the nut securing the starter motor to the lower mounting stud on the transmission torque converter housing.
  9. Tighten the upper starter motor mounting screw. Tighten the screw to 67.8 N.m (50 ft. lbs.).
  10. Tighten the lower starter motor mounting nut. Tighten the nut to 67.8 N.m (50 ft. lbs.).
  11. Lower the vehicle.
  12. Reconnect the battery negative cable.

Installation (3.3L & 3.8L)

  1. Place starter spacer in position on transaxle bellhousing, flange toward flywheel.
  2. Place starter in position on bellhousing.
  3. Install bolts to hold starter to transaxle bellhousing.
  4. Connect solenoid connector into starter.
  5. Install nut to hold B+ terminal to starter solenoid.
  6. Lower vehicle.
  7. Connect battery negative cable.
  8. Verify starter operation.

Installation (5.9L Diesel)

  1. Position the starter motor in the engine compartment.
  2. While supporting the starter motor with one hand, use the other hand to loosely install the three screws that secure the starter motor to the flywheel housing.
  3. Tighten the three starter motor mounting screws. Tighten the screws to 43.4 N.m (32 ft. lbs.).
  4. Install the battery positive cable wire harness connector eyelets over the solenoid terminal studs.
  5. Install and tighten the nut that secures the battery positive cable wire harness connector eyelet to the solenoid terminal stud. Tighten the nut to 6.2 N.m (55 in. lbs.).
  6. Install and tighten the nut that secures the battery positive cable wire harness connector eyelet to the solenoid battery terminal stud. Tighten the nut to 13.6 N.m (120 in. lbs.).
  7. Install the protective rubber boot on the battery positive cable wire harness over the solenoid battery terminal stud and connector eyelet.
  8. Lower the vehicle.
  9. Reconnect the negative cables to both batteries.

Installation (8.0L)

  1. Position the starter motor in the engine compartment.
  2. While supporting the starter motor with one hand, use the other hand to loosely install the two screws that secure the starter motor to the engine.
  3. Tighten the two starter motor mounting screws. Tighten the screws to 67.8 N.m (50 ft. lbs.).
  4. Reconnect the battery positive cable wire harness connector to the solenoid terminal connector receptacle.
  5. Install the battery positive cable wire harness connector eyelet over the solenoid battery terminal stud.
  6. Install and tighten the nut that secures the battery positive cable wire harness connector eyelet to the solenoid battery terminal stud. Tighten the nut to 13.6 N.m (120 in. lbs.).
  7. Lower the vehicle.
  8. Reconnect the battery negative cable.

OVERHAUL

Note. Manufacturer does not recommend disassembling and servicing starters. If starter is found defective, a new unit must be installed.

STARTER SPECIFICATIONS

ApplicationSpecification
Cranking Amperage Draw (1)
Bosch 2.0L150-280 Amps
Melco 2.5L & 2.7L150-280 Amps
Nippondenso 2.4L, 3.2L & 3.5L150-280 Amps
No-Load Test At 11 Volts
Maximum Amps
Bosch 2.0L(2)
Melco 2.5L & 2.7L(2)
Nippondenso 2.4L, 3.2L & 3.5L(2)
No-Load Test At 11 Volts
Minimum RPM
Bosch 2.0L(2)
Melco 2.5L & 2.7L(2)
Nippondenso 2.4L, 2.7L & 3.5L(2)
Power Rating
Bosch 2.0L0.95 Kw
Melco 2.5L & 2.7L1.2 Kw
Nippondenso 2.4L, 2.7L & 3.5L1.4 Kw
(1) With engine at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw. (2) Information is not available from manufacturer.
(1)With engine at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw.
(2)Information is not available from manufacturer.

STARTER SPECIFICATIONS - CARS

ApplicationSpecification
Cranking Amperage Draw (1)
Caravan, Town & Country & Voyager150-200 Amps
Dakota & Durango
2.5L130 Amps
3.9L, 5.2L & 5.9L125-250 Amps
Ram Pickup
Diesel Engines450-700 Amps
Gasoline Engines125-250 Amps
Ram Van & Ram Wagon125-250 Amps
No-Load Test At 11 Volts
Maximum Amps
Caravan, Town & Country & Voyager73 Amps
Dakota & Durango
2.5L90 Amps
3.9L, 5.2L & 5.9L73 Amps
Ram Pickup
Gasoline73 Amps
Diesel200 Amps
Ram Van & Ram Wagon73 Amps
Minimum RPM
Caravan, Town & Country & Voyager3401 RPM
Dakota & Durango
2.5L2600 RPM
3.9L, 5.2L & 5.9L3601 RPM
Ram Pickup
Gasoline3601 RPM
Diesel3000 RPM
Ram Van & Ram Wagon3601 RPM
Power Rating
Caravan, Town & Country & Voyager1.2 Kw
Dakota & Durango
2.5L1.2 Kw
3.9L, 5.2L & 5.9L1.4 Kw
Ram Pickup
Gasoline1.4 Kw
Diesel2.7 Kw
Ram Van & Ram Wagon1.4 Kw
(1) With engine at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw.
(1)With engine at normal operating temperature. High viscosity oil, extreme cold temperatures, or tight engine will increase amperage draw.

STARTER SPECIFICATIONS - TRUCKS

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Starter Mounting Bolts & Nuts
All Except Dakota, Durango, Ram Pickup, Ram Van & Ram Wagon40 (54)
Dakota & Durango
2.5L33 (45)
3.9L, 5.2L & 5.9L50 (68)
Ram Pickup
Diesel Engines32 (43)
Gasoline Engines50 (68)
Ram Van & Ram Wagon50 (68)

TORQUE SPECIFICATIONS - CARS & TRUCKS

Scheme 4: Starting System Wiring Diagram (Breeze, Cirrus & Stratus)
Scheme 5: Starting System Wiring Diagram (Caravan, Town & Country, & Voyager)
Scheme 6: Starting System Wiring Diagram (Concorde, Intrepid, LHS & 300M)
Scheme 7: Starting System Wiring Diagram (Dakota)
Scheme 8: Starting System Wiring Diagram (Durango)
Scheme 9: Starting System Wiring Diagram (Neon)
Scheme 10: Starting System Wiring Diagram (Ram Pickup)
Scheme 11: Starting System Wiring Diagram (Ram Van & Ram Wagon)