Starting System: Removal & Installation Dodge Pickup R2500

INSTALLATION 3.7L / 4.7L

1. Connect solenoid wire to starter motor (snaps on).
2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. See «TORQUE SPECIFICATIONS»(ref-164936-S37908849162004081800000) . Do not allow starter motor to hang from wire harness.
3. Position starter motor to transmission.
4. If equipped with automatic transmission, slide cooler tube bracket into position.
5. Install and tighten both bolts (auto. trans.), or 1 nut and 1 bolt (man. trans.). See «TORQUE SPECIFICATIONS»(ref-164936-S37908849162004081800000) .
6. Lower vehicle.
7. Connect negative battery cable.

REMOVAL 5.7L GAS

1. Disconnect and isolate negative battery cable.
2. Raise and support vehicle.
3. Note: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.
4. Remove 2 mounting bolts. (Scheme 9)
5. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire harness.
6. Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
7. Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud.
8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle.
9. Remove starter motor.

Scheme 9

INSTALLATION 5.7L GAS

1. Connect solenoid wire to starter motor (snaps on).
2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. See «TORQUE SPECIFICATIONS»(ref-164936-S37908849162004081800000) . Do not allow starter motor to hang from wire harness.
3. Position starter motor to engine.
4. If equipped with automatic transmission, slide cooler tube bracket into position.
5. Install and tighten both mounting bolts. See «TORQUE SPECIFICATIONS»(ref-164936-S37908849162004081800000) .
6. Lower vehicle.
7. Connect negative battery cable.

Scheme 10

1. Disconnect and isolate both negative battery cables at both batteries.
2. Raise and support vehicle.
3. Remove 3 starter mounting bolts. (Scheme 10)
4. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process. Do not let starter motor hang from wire harness.
5. Tilt nose downwards and lower starter motor far enough to access and remove nuts securing starter wiring harness to starter. (Scheme 11) Do not let starter motor hang from wire harness.
6. Remove starter motor from engine. Note: Certain diesel engines use an aluminum spacer. (Scheme 10) Note position and orientation of spacer before removal.

Scheme 11

INSTALLATION 5.9L DIESEL

1. If Equipped: Position and hold aluminum spacer to rear of starter while positioning starter to engine.
2. Connect solenoid wire to starter motor. Tighten nut.
3. Position battery cable to starter stud. Install and tighten battery cable nut. See «TORQUE SPECIFICATIONS»(ref-164936-S37908849162004081800000) . Do not allow starter motor to hang from wire harness.
4. Position starter motor to transmission.
5. If equipped with automatic transmission, slide cooler tube bracket into position.
6. Install and tighten 3 starter mounting bolts. See «TORQUE SPECIFICATIONS»(ref-164936-S37908849162004081800000) .
7. Lower vehicle.
8. Connect both negative battery cables to both batteries.

Scheme 12

Scheme 13

Scheme 14

1. Disconnect the negative battery cable.
2. Raise vehicle and support. (Scheme 12)
3. Disconnect the solenoid connector.
4. Remove the positive battery cable. (Scheme 13)
5. Remove the upper bolt. (Scheme 14)
6. Remove the lower bolt.
7. Remove the starter.

INSTALLATION 8.3L - SRT-10

1. Install the starter.
2. Install the lower bolt.
3. Install the upper bolt. (Scheme 14)
4. Install the positive battery cable. (Scheme 13)
5. Connect the solenoid connector.
6. Lower vehicle.
7. Connect the negative battery cable.

REMOVAL

The starter relay is located in the Power Distribution Center (PDC). (Scheme 15) Refer to label on PDC cover for relay location.

1. Disconnect and isolate negative battery cable.
2. Remove cover from Power Distribution Center (PDC) for relay identification and location.
3. Remove starter relay from PDC.
4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.
5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay.

INSTALLATION

1. Push down firmly on starter relay until terminals are fully seated in PDC receptacle.
2. Install PDC cover.
3. Connect battery cable.

Scheme 15

STARTING SYSTEM SPECIFICATIONS