2002 Dodge Truck Starting Problem

Hi icedak02. Welcome to the forum. Did you install a used or a rebuilt starter? This is a real common problem with the little silver Nippensenso starter. The solenoid contacts wear down from the normal arcing. They can be replaced for 20 bucks but most people just replace the entire starter. Since the problem persists after you did so, I'm hoping you installed a used starter that most likely has the same problem.

If you used a rebuilt starter, you might consider connecting a test light's ground wire / clip to the large battery cable terminal right on the starter, running the light inside the truck, and grounding it there with a clip lead when you hop in to start it. If the light goes out when you try to crank the engine, you have a cable problem that we can narrow down. If the light stays on when the starter just clicks, the problem is in the starter.

Caradiodoc

The 11.89 volts indicates the starter is not drawing any current, and since the voltage is still there at the cable on the starter, that proves the cable isn't the problem. That leaves the new starter as the problem. Just to be safe, move the voltmeter's ground wire to the engine block. That will include the negative battery cable in the test, but if it were the problem. I would expect you to hear a rapid clicking of the starter solenoid, not the single clunk you're getting.

Do you in fact have the little silver Nippendenso starter? They're common on the front-wheel-drive cars and minivans but I have seen them on trucks too. Because of their gear reduction, they are plenty strong enough to spin a small V-8 engine. If you have this starter, you might be able to lift the rubber cover to access the other large terminal after the solenoid. That one should get battery voltage when the solenoid engages. If you only find a volt or two there when you turn the ignition switch to "crank", (or 0 volts), you'll know for sure the solenoid is the problem.

Caradiodoc

Yup, you gots a Nippendenso starter. They're a very nice piece except for those contacts. There are repair kits available that include the plunger with the contact disc but I don't replace the plungers anymore. It has proven to be an unnecessary expense MOST of the time. For that reason, the rebuilder might have just replaced the contacts too but you might have gotten the one out of a hundred that needed the plunger.

Caradiodoc

Dandy! It's nice to read once in a while that someone is NOT having a problem.

Caradiodoc