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Replaced one wire on the starter. Now truck will not start, no click at key turn.

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Hey guys.

2001 2500 24v 6speed manual.

Always has started perfect and fast.

I noticed a very loose wire on the starter yesterday (the smaller wire).

I was going to pull the wire off, strip it down a little then reinstall it to get a better connection.

I wasnt thinking when I first got under it with pliers to loosen the nut. I must of touched something together because I got a spark and a loud noise. Almost like it tried to turn over.

Disconnected the batteries so that wouldn't happen again. Pulled the wire off, stripped it down to good wire, wound it around the grounding post and tightened a nut down on it.

Reattached the batteries, turn the key to start, all the lights come on, accessories work, etc.

But when I turn the key to start I get nothing though, not even a click. Did I fry something when I touched the starter with pliers?

I checked all connections, they look good. I can't tell if my relay is good.

Is there anyway I can jump the starter from underneath to see if it is still good?

The starter is nearly brand new from auto zone, but I noticed as I was trying to remove the nut on the mounting post for the smaller wire the mounting post was just turning. Like it was loose inside the starter?

I just replaced the starter relay, and 40 amp solenoid fuse 20 min ago, still nothing, not even a click. Once again all accessories work, WTS light works, etc.

What did I do?

Thanks guys

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Yikes! I do believe there is superposed to be a starter spacer on your truck, my guess would be its missing for that to happen to the starter.

Yeah thats what I thought when I pulled it off lol From what I've been able to find out. Starter spacers are required for use with dual disk clutches. The previous owner did not have a spacer on it either so the truck must have done the same thing to the old starter. These cummins are tough, they eat starters for fun. Now I just need to find a spacer by Saturday. Or preferably tomorrow...when I have time to work on it.

There is a spacer that goes on the starter. They are year specific, my 02 has one. Not sure which years they go on, but I would think yours needs one.

I'm learning A LOT I didn't know! Just a thought ,since the other starter wasn't hitting the ring gear,do you think the spacer might have been stuck to the nose of the starter that was returned? Or are there different starters, and it's a crap shoot which one you get when purchasing a Reman?

In a pinch, use washers. Been there done that. Temporarily, though. Sent from my SPH-L710 using Tapatalk 2

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There was no spacer on the old starter thanks to the clueless ex owner. It was the exact same model as the new one I installed. I am assuming that it also was ground down by the previous owner.

Looked all over for a spacer. Called Wooster Diesel and they happened to have a spacer!

It was the solution to my problems. Starter fits and works great now.

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Now I just need to find the correct fuel hose to fix the leaking lift pump to fuel filter hose and I should be good to go.

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Glad you were able to find a spacer at Wooster diesel :thumb1:

yeah man I didnt even think about giving them a call until this morning. Awesome they had one, I was in the car heading their way asap. They have a good setup there.
  • 5 weeks later...

If anyone ever does the jumper wire in the clutch safety switch be sure you are always sitting in the seat before you start it. That way you won't have a truck drive thru the garage and no one to stop it. Yes it happened to me :whistle:. I found out almost nothing will stop a Cummins till you reach inside and turn off the key

Happened to me too ..... mine knocked over my neighbor's fence before I could jump in and hit the clutch. Always wanted to be a fence builder anyway! Greg :doh:
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