Dodge Ram Truck 1500-2500-3500. Manual — part 336

3. Disconnect the solenoid connector.

4. Remove the positive battery cable.

5. Remove the upper bolt.

6. Remove the lower bolt.

7. Remove the starter.

INSTALLATION

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. Refer to Torque Specifications.

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.). Refer to Torque Specifications.

6. Lower vehicle.

7. Connect negative battery cable.

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5.7L

1. Connect solenoid wire to starter motor (snaps on).

2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications.

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. Refer to Torque Specifications.

6. Lower vehicle.

7. Connect negative battery cable.

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. Refer to Torque Specifications. 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. Refer to Torque Specifications.

7. Lower vehicle.

8. Connect both negative battery cables to both batteries.

8.3L - SRT-10

1. Install starter.

2. Install lower bolt.

3. Install upper bolt.

4. Install positive battery cable.

5. Connect solenoid connector.

6. Lower vehicle.

7. Connect negative battery cable.

STARTER MOTOR RELAY

DESCRIPTION

The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter sole-
noid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center
(PDC) in the engine compartment. See PDC cover for relay identification and location.

The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have
common physical dimensions, current capacities, terminal patterns, and terminal functions.

The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced.

OPERATION

The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) elec-
trical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed)
by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally
closed fixed contact, and holds it against the other (normally open) fixed contact.

When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position.
The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage
spikes produced when coil is de-energized.

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DIAGNOSIS AND TESTING

STARTER RELAY

The starter relay is located in Power Distribution Cen-
ter (PDC). Refer to PDC cover for relay identification
and location. For complete starter relay wiring circuit
diagrams, refer to 8, Wiring Diagrams.

1. Remove starter relay from PDC.

2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between

terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay.

3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK,

replace faulty relay.

4. Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and

no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace
faulty relay.

RELAY CIRCUIT TEST

1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK,

go to Step 2. If not OK, repair open circuit to fuse in PDC as required.

2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used

for this application. Go to Step 3.

3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This

terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay
terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter
solenoid as required.

4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held

in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check
for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when igni-
tion switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open
or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch
and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal
position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch in 6 , Clutch.

5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmis-

sion, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral
position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground
at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK
with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required.
If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch in 21, Transmission.

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REMOVAL

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

1. Disconnect and isolate negative battery cable.

2. Remove cover (2) 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 into PDC receptacle.

2. Install PDC cover.

3. Connect battery cable.

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