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

[jshalala]

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

[CUMMINSDIESELPWR]

check fuses and relays first. dont want to weld those contacts with something...

[bry1216]

Starting System 98-02 Dodge Ram Service Manual.pdf Attach is the wiring schematic. Since it is a manual, there should be a switch on the clutch.

[jshalala]

Is there anyway to bypass the clutch position sensor? I want to rule that out of the equation.

[bjytech]

Is there anyway to bypass the clutch position sensor? I want to rule that out of the equation.

Yes there is, all you have to do is find the plug for it up under the dash by the top of the clutch pedal arm and put a jumper in the plug.

[angus]

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

That stud you are refering to is connected to a conductor strap inside the solinoid housing... When the stud is turning it usually means it has twisted the strap in two.. My son did this same thing, and had to replace the starter.

You could pull the starter, and take the cover off the solinoid housing just to be sure.. It will be quite evident if thats the case.

[jshalala]

That stud you are refering to is connected to a conductor strap inside the solinoid housing... When the stud is turning it usually means it has twisted the strap in two.. My son did this same thing, and had to replace the starter. You could pull the starter, and take the cover off the solinoid housing just to be sure.. It will be quite evident if thats the case.

I believe sir, you have hit the nail on the head. I was afraid of that, kinda figured that might be what happened. Thankfully I have lifetime replacement on the starter so I will pull it tomorrow, swap it for a new one and see if I can get it figured out.

[JAG1]

Yes there is, all you have to do is find the plug for it up under the dash by the top of the clutch pedal arm and put a jumper in the plug.

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 . I found out almost nothing will stop a Cummins till you reach inside and turn off the key

[diesel4life]

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 . I found out almost nothing will stop a Cummins till you reach inside and turn off the key

I'm almost afraid to ask what stopped it...

[JAG1]

I'm almost afraid to ask what stopped it...

The table saw and two work benches, including the one that was out in the middle was just starting to get pushed thru the back wall into the front of the tractor parked in back, when I finally got my hands on the key. I learned real quick why they put Cummins in heavy equipment like a cat.

[jshalala]

Is M10-1.50 x 35mm the correct size for the starter bolts?

I am missing the upper bolt, would like to pick one up at the hardware store tomorrow.

[bjytech]

I know they are M10x1.5 and either 35 or 40 for length.

[sngsht]

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 . I found out almost nothing will stop a Cummins till you reach inside and turn off the key

Now that, would get the old ticker going!!!

[Mopar1973Man]

Check the starter solenoid fuse. I've seen fuse crack instead of blowing out so check it with a ohm meter.Check the starter solenoid relay. You can swap with something else.If you put 12 volt power to that brown wire it should turn over.

[jshalala]

Update:

Pulled the starter and the end cap off the starter and the wire post that connects to the brown wire had broken off inside of the starter.

I will be picking up a replacement starter in about an hour and hope to be up and running later today.

- - - Updated - - -

ANOTHER update:

Is there a special procedure to install the starter?

I bolted it up, tightened all the wires down and it fired right up.

But while the truck is running I swear I can hear the starter motor still running. I turn the key to start position again (while it is running) and I dont hear it grind like when you normally attempt to start an already running engine. I feel like the starter is not disengaging? Is that even possible?

[bry1216]

Update:

Pulled the starter and the end cap off the starter and the wire post that connects to the brown wire had broken off inside of the starter.

I will be picking up a replacement starter in about an hour and hope to be up and running later today.

- - - Updated - - -

ANOTHER update:

Is there a special procedure to install the starter?

I bolted it up, tightened all the wires down and it fired right up.

But while the truck is running I swear I can hear the starter motor still running. I turn the key to start position again (while it is running) and I dont hear it grind like when you normally attempt to start an already running engine. I feel like the starter is not disengaging? Is that even possible?

Open attachment and view 8F - 34 & 8F - 40 . Maybe you shorted starter relay or bad starter. [ATTACH]5623[/ATTACH]

Engine Starter.pdf

[bjytech]

Either the new starter has a bad solenoid, the starter solenoid is sticking or the solenoid is getting power all the time for some reason.First thing I would do is double check the wires and relays, after that you could pull the starter and check to make sure the solenoid isn't sticking but chances are the starter solenoid is defective.

[jshalala]

Thanks guys. I'll pull the starter again tomorrow and double check everything. They bench tested it for me at the store before I took it so I cannot imagine the starter is bad already. Will pulling the starter relay while the truck is running do anything? I would think if I pulled the relay and I heard the starter stop running that I could pinpoint the problem. The previous owner did A LOT of crappy wiring when installing aftermarket or replacement parts. I am hoping he didnt somehow bypass a relay. I'll figure this thing out someday lol I need the truck by Saturday. So I have a couple days

[bjytech]

Thanks guys. I'll pull the starter again tomorrow and double check everything. They bench tested it for me at the store before I took it so I cannot imagine the starter is bad already. Will pulling the starter relay while the truck is running do anything? I would think if I pulled the relay and I heard the starter stop running that I could pinpoint the problem. The previous owner did A LOT of crappy wiring when installing aftermarket or replacement parts. I am hoping he didnt somehow bypass a relay. I'll figure this thing out someday lol I need the truck by Saturday. So I have a couple days

Yes if you pull the relay while the starter is running it should disengage it. If that works try switching the relay with another one and see if it works right, then you know if its in the relay or not.

[jshalala]

I may win the idiot of the year award.

The noise I thought was the starter running? It was this going on.

How is that possible? Is there a certain way the starters need to be installed?

The noise I heard must have been the flywheel grinding down the nose of the starter....

I had Autozone pull up the part number for a 01 24v 7 code engine and this is what they gave me...idk