Starting System Dodge Ram Van III

DESCRIPTION

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 .

STARTER APPLICATIONS

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article.

REMOVAL

1. Disconnect and isolate the battery negative cable.
2. Raise and support the vehicle.
3. Remove the nut and lock washer from the starter mounting stud. Slide the automatic transmission cooler tube bracket forward on the tubes far enough for clearance.
4. Remove the screw from the upper starter mounting flange hole.
5. Move the starter towards the front of the vehicle until the starter gear housing nose clears the bellhousing. Then tilt the nose downwards and lower the starter far enough to access the starter solenoid wire harness connector.
6. Remove the two nuts that secure the battery cable and solenoid feed wire to the terminals on the starter solenoid. Remove the starter solenoid wire harness connector from the solenoid terminals.
7. Remove the starter motor from the vehicle.

INSTALLATION

Reverse the removal procedures to install. Tighten the starter hardware as follows

1. Lower mounting nut - 68 N.m (50 ft. lbs.)
2. Upper mounting screw - 68 N.m (50 ft. lbs.)
3. Battery cable terminal nut - 14 N.m (120 in. lbs.)
4. Solenoid wire harness terminal nut - 6 N.m (55 in. lbs.)

* PLEASE READ FIRST *

DISABLING/ENABLING IGNITION & 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 SYSTEM/COMPONENT TESTS article in the ENGINE PERFORMANCE Section

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/ram-van/iii-1994-2003/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/ram-van/iii-1994-2003/remont/starter/#starting-system__circuit-resistance-tests) . Refer to «STARTER SPECIFICATIONS»(/dodge/ram-van/iii-1994-2003/remont/starter/#starting-system__starter-specifications) .
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/ram-van/iii-1994-2003/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/ram-van/iii-1994-2003/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) If engine cranks, solenoid and starter are good. Go to «STARTER RELAY TEST»(/dodge/ram-van/iii-1994-2003/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/ram-van/iii-1994-2003/remont/starter/#starting-system__solenoid-test) 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) Using ohmmeter, check continuity across starter relay terminals No. 30 and 87. If continuity is not present, replace starter relay.

Scheme 1

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) If engine does not crank, go to «SOLENOID TEST»(/dodge/ram-van/iii-1994-2003/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/ram-van/iii-1994-2003/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)»(/dodge/ram-van/iii-1994-2003/remont/starter/#starting-system__parkneutral-position-pnp-switch-transmission) SENSOR TEST.

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

Note. The following test is for RWD Van, with 3-speed transmission. All other models are equipped with a Transmission Range (TR) sensor. If TR sensor or sensor circuit is defective, a Diagnostic Trouble Code (DTC) should set. See TESTS W/CODES article in the ENGINE PERFORMANCE Section.

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/SAFETY EQUIPMENT Section.

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.

OVERHAUL

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

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• COMPUTER RELEARN PROCEDURES
• STEERING COLUMN SWITCHES
• WIRING DIAGRAMS
• DISABLING/ENABLING IGNITION & FUEL SYSTEMS
• CIRCUIT RESISTANCE TESTS
• STARTER SPECIFICATIONS
• STARTER RELAY TEST
• SOLENOID TEST
• SOLENOID CIRCUIT TEST
• CLUTCH POSITION SWITCH TEST
• PARK/NEUTRAL POSITION (PNP) SWITCH & TRANSMISSION RANGE (TR)