Dodge Ram Truck 1500-2500-3500. Manual — part 334
solenoid, you are reading combined voltage drop in positive battery cable clamp-to-terminal post connection and
positive battery cable.
The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing tests, be certain that
following procedures are accomplished:
•
Battery is fully-charged and load-tested. Refer to Battery in 8, Battery.
•
Fully engage parking brake.
•
If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal
in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park posi-
tion.
•
Verify that all lamps and accessories are turned off.
•
To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel
engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC).
Refer to label on PDC cover for relay location.
1. Connect positive lead of voltmeter (1) to negative
battery cable terminal post. Connect negative lead
of voltmeter to negative battery cable clamp.
Rotate and hold ignition switch in Start position.
Observe voltmeter. If voltage is detected, correct
poor contact between cable clamp and terminal
post. Note: Certain diesel equipped models use
dual batteries. If equipped with dual battery
system, procedure must be performed twice,
once for each battery.
2. Connect positive lead of voltmeter to positive bat-
tery terminal post. Connect negative lead of volt-
meter to battery positive cable clamp. Rotate and
hold ignition switch in Start position. Observe volt-
meter. If voltage is detected, correct poor contact
between cable clamp and terminal post. Note: Cer-
tain diesel equipped models use dual batteries.
If equipped with dual battery system, this pro-
cedure must be performed twice, once for each
battery.
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3. Connect voltmeter to measure between battery
positive terminal post and starter solenoid battery
terminal stud. Rotate and hold ignition switch in
Start position. Observe voltmeter. If reading is
above 0.2 volt, clean and tighten battery cable con-
nection at solenoid. Repeat test. If reading is still
above 0.2 volt, replace faulty positive battery cable.
Note: Certain diesel equipped models use dual
batteries. If equipped with dual battery system,
this procedure must be performed on driver
side battery only.
4. Connect voltmeter to measure between negative
battery terminal post and a good clean ground on
engine block. Rotate and hold ignition switch in
Start position. Observe voltmeter. If reading is
above 0.2 volt, clean and tighten negative battery
cable attachment on engine block. Repeat test. If
reading is still above 0.2 volt, replace faulty nega-
tive battery cable. Note: Certain diesel equipped
models use dual batteries. If equipped with dual
battery system, this procedure must be per-
formed twice, once for each battery.
5. Connect positive lead of voltmeter to starter hous-
ing. Connect negative lead of voltmeter to negative
battery terminal post. Rotate and hold ignition
switch in Start position. Observe voltmeter. If read-
ing is above 0.2 volt, correct poor starter to engine
block
ground
contact.
Note:
Certain
diesel
equipped
models
use
dual
batteries.
If
equipped with dual battery system, this proce-
dure must be performed on driver side battery
only.
6. If equipped with dual battery system (certain diesel
equipped models), connect positive lead of voltme-
ter to positive battery cable clamp on battery
located on left side of vehicle. Connect negative
lead of voltmeter to positive battery terminal post
on battery located on right side of vehicle. Rotate and hold ignition switch in Start position. Observe voltmeter. If
reading is above 0.2 volt, clean and tighten battery cables at both batteries. Repeat test. If reading is still above
0.2 volt, replace faulty positive battery cable.
If resistance tests detect no feed circuit problems, refer to Starter Motor in the Diagnosis and Testing.
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CONTROL CIRCUIT TESTING
The starter control circuit components should be tested in the order in which they are listed, as follows:
•
Starter Relay - Refer to Starter Relay Diagnosis and Testing.
•
Starter Solenoid - Refer to Starter Motor Diagnosis and Testing.
•
Ignition Switch - Refer to Ignition Switch and Key Lock Cylinder
•
Clutch Pedal Position Switch - If equipped with manual transmission, refer to Clutch Pedal Position Switch
in 6, Clutch.
•
Park/Neutral Position Switch - If equipped with automatic transmission, refer to Park/Neutral Position
Switch in 21, Transmission.
•
Wire harnesses and connections - Refer to 8, Wiring Diagrams.
SPECIFICATIONS
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer
Denso
Denso
Part Number
56028715AD
4741012
Engine Application
3.7L / 4.7L / 5.7L
5.9L Diesel
Power Rating
1.4 Kilowatt / 1.9
Horsepower
2.7 Kilowatt / 3.6
Horsepower
Voltage
12 Volts
12 Volts
Number of Brushes
4
4
Drive Type
Gear Reduction
Conventional
Free Running Test Voltage
11 Volts
11 Volts
Free Running Test Amperage
Draw
73 Amperes
200 Amperes
Free Running Test Minimum
Speed
3601 rpm
3000
Solenoid Closing Maximum
Voltage Required
7.5 Volts
8.0 Volts
* Cranking Amperage Draw
Test
125 - 250 Amperes
450 - 700 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter
amperage draw.
STARTER - 8.3L - SRT-10
Engine Application
8.3L (V 10)
Power rating
2.0 Kw
Voltage
12 VOLTS
No. of Fields
4
No. of Poles
4
Brushes
4
Drive
Offset Reduction Gear
Cranking Amperage Draw test
150 - 280 Amps.
Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage
draw.
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TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Battery Cable Eyelet Nut
at Solenoid (large nut -
gas engines)
25
19
221
Battery Cable Eyelet Nut
at Solenoid (large nut -
diesel engine)
14
-
120
Starter Solenoid Nut
(small nut - diesel engine)
6
-
55
Starter Mounting Bolts -
Gas Engines
68
50
-
Starter Mounting Nut -
Gas Engines
68
50
-
Starter Mounting Bolts -
Diesel
43
32
-
Starter Mounting Bolts
8.3L
40
30
-
Starter Battery Cable Nut
8.3L
10
-
90
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed by performing the following free running bench test. This test can
only be performed with starter motor removed from vehicle. Refer to Specifications for starter motor specifications.
1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation.
2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting
flange of starter motor. Never clamp on starter motor by field frame.
3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100
ampere scale. See instructions provided by manufacturer of volt-ampere tester being used.
4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter
motor fails to operate, replace faulty starter motor assembly.
5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free
running test voltage specifications.
6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Speci-
fications for starter motor free running test maximum amperage draw specifications.
7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly.
STARTER SOLENOID
This test can only be performed with starter motor removed from vehicle.
1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation.
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STARTING
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