Dodge Dakota (R1). Manual — part 303
(5) Connect positive lead of voltmeter to starter
housing. Connect negative lead of voltmeter to bat-
tery negative terminal post (Fig. 6). Rotate and hold
ignition switch in Start position. Observe voltmeter.
If reading is above 0.2 volt, correct poor starter to
engine block ground contact. Note: If equipped
with a dual battery system (diesel), this proce-
dure must be performed on driver side battery
only.
(6) If equipped with dual battery system (diesel),
connect positive lead of voltmeter to driver side bat-
tery positive cable clamp. Connect negative lead of
voltmeter to passenger side battery positive terminal
post. Rotate and hold ignition switch in Start posi-
tion. Observe voltmeter. If reading is above 0.2 volt,
clean and tighten passenger side battery positive
cable eyelet connection at driver side battery positive
cable clamp bolt. Repeat test. If reading is still above
0.2 volt, replace faulty passenger side battery posi-
tive cable.
If resistance tests detect no feed circuit problems,
refer to Starter Motor in the Diagnosis and Testing.
CONTROL CIRCUIT TESTING
The starter control circuit components should be
tested in the order in which they are listed, as fol-
lows:
• Starter Relay - Refer to Starter Relay Diag-
nosis 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
SPECIFICATIONS - STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer
Mitsubishi
Denso
Denso
Part Number
56041013AC
56027702AC
56028715
Engine Application
2.5L
3.9L, 4.7L (Manual), 5.9L
4.7L (Auto)
Power Rating
1.2 Kilowatt - (1.6
Horsepower)
1.4 Kilowatt - (1.9
Horsepower
1.4 Kilowatt - (1.9
Horsepower
Voltage
12 Volts
12 Volts
12 Volts
Pinion Teeth
9
10
10
Number of Fields
4
4
4
Number of Poles
4
4
4
Number of Brushes
4
4
4
Drive Type
Planetary Gear
Reduction
Reduction Gear Train
Reduction Gear Train
Free Running Test Voltage
11.2 Volts
11 Volts
11 Volts
Fig. 6 Test Starter Ground - Typical
1 - STARTER MOTOR
2 - BATTERY
3 - VOLTMETER
8F - 34
STARTING
AN
STARTING (Continued)
Starter Motor and Solenoid
Free Running Test Maximum
Amperage Draw
90 Amperes
73 Amperes
73 Amperes
Free Running Test Minimum
Speed
2600 rpm
3601 rpm
3601 rpm
Solenoid Closing Maximum
Voltage Required
7.8 Volts
7.5 Volts
7.5 Volts
* Cranking Amperage Draw
Test
130 Amperes
125 - 250 Amperes
125 - 250 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
SPECIFICATIONS - TORQUE - STARTING SYSTEM
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Battery Cable Eyelet Nut at Solenoid Stud
14
120
Starter Mounting Bolts – 2.5L Engine
54
40
Starter Mounting Nuts/Bolts – V-6/V-8 Engines
68
50
STARTER MOTOR
DESCRIPTION
The 2.5L starter is mounted with two bolts to the
clutch housing on the right side of the engine. The
4.7L
automatic
transmission
starter
motor
is
mounted with two bolts to the torque converter hous-
ing on the left side of the engine. The starter motors
for all of the remaining engine and transmission
combinations are mounted with one bolt, a stud and
a nut to the clutch or convertor housing, and are
located on the left side of the engine.
The electric motors of both starters have four
brushes contacting the motor commutator. The 2.5L
starter motor uses four permanent magnets for the
field poles, while the other starter motors feature
four electromagnetic field coils wound around four
pole shoes.
The starter motors are serviced only as a unit with
starter solenoids, and cannot be repaired. If either
component is faulty or damaged, the entire starter
motor and starter solenoid unit must be replaced.
OPERATION
The starter motor is equipped with a gear reduc-
tion (intermediate transmission) system. The gear
reduction system consists of a gear that is integral to
the output end of the electric motor armature shaft
that is in continual engagement with a larger gear
that is splined to the input end of the starter pinion
gear shaft. This feature makes it possible to reduce
the dimensions of the starter. At the same time, it
allows higher armature rotational speed, and delivers
increased torque through the starter pinion gear to
the starter ring gear.
The starter motor is activated by an integral heavy
duty starter solenoid switch mounted to the overrun-
ning clutch housing. This electromechanical switch
connects and disconnects the feed of battery voltage
to the starter motor, and actuates a shift fork that
engages and disengages the starter pinion gear with
the starter ring gear.
The starter motor uses an overrunning clutch and
starter pinion gear unit to engage and drive the
gears on the flywheel (or flywheel ring gear).
DIAGNOSIS AND TESTING - STARTER MOTOR
Correct starter motor operation can be confirmed
by performing following free running bench test. This
test can only be performed with starter motor
removed from vehicle. Refer to Starting Specifica-
tions for starter motor specifications.
(1) Remove starter motor from vehicle. Refer to
Starter MotorRemoval and Installation.
(2) Mount starter motor securely in a soft-jawed
bench vise. The vise jaws should be clamped on
mounting flange of starter motor. Never clamp on
starter motor by field frame.
(3) Connect suitable volt-ampere tester and 12-volt
battery to starter motor in series, and set ammeter to
100 ampere scale. See instructions provided by man-
ufacturer 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.
AN
STARTING
8F - 35
SPECIFICATIONS
(Continued)
(5) Adjust carbon pile load of tester to obtain free
running test voltage. Refer to Starting Specifications
for starter motor free running test voltage specifica-
tions.
(6) Note reading on ammeter and compare reading
to free running test maximum amperage draw. Refer
to Starting Specifications section for starter motor
free running test maximum amperage draw specifica-
tions.
(7) If ammeter reading exceeds maximum amper-
age draw specification, replace faulty starter motor
assembly.
STARTER MOTOR 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.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal
and solenoid field coil terminal with continuity tester
(Fig. 7) or (Fig. 8). There should be continuity. If OK,
go to Step 4. If not OK, replace faulty starter motor
assembly.
(4) Check for continuity between solenoid terminal
and solenoid case (Fig. 9) or (Fig. 10). There should
be continuity. If not OK, replace faulty starter motor
assembly.
REMOVAL
2.5L Engine
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove bolt and washer (forward facing) secur-
ing starter to clutch housing (Fig. 11).
(4) While supporting starter motor, remove bolt
and washer (rearward facing) securing starter motor
to transmission housing.
(5) Lower starter motor far enough to access and
remove battery cable eyelet terminal nut at starter
solenoid. Always support starter motor during this
process. Do not let starter motor hang from wire har-
ness.
(6) Remove battery cable from stud.
(7) Disconnect solenoid terminal wire harness con-
nector from starter solenoid.
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - 2.5L Engine - Typical
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
4 - FIELD COIL TERMINAL
Fig. 8 Continuity Test Between Solenoid Terminal
and Field Coil Terminal - 3.9L/4.7L/5.9L Engine -
Typical
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL
Fig. 9 Continuity Test Between Solenoid Terminal
and Solenoid Case - 2.5L Engine - Typical
1 - SOLENOID
2 - SOLENOID TERMINAL
3 - OHMMETER
Fig. 10 Continuity Test Between Solenoid Terminal
and Solenoid Case - 3.9L/4.7L/5.9L Engine - Typical
1 - SOLENOID TERMINAL
2 - OHMMETER
3 - SOLENOID
8F - 36
STARTING
AN
STARTER MOTOR (Continued)
(8) Remove starter motor from transmission hous-
ing.
All 3.9L/5.9L, or 4.7L With Manual Transmission
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove nut securing starter motor to stud on
transmission housing (Fig. 12).
(4) While supporting starter motor, remove bolt
securing starter motor to transmission housing.
(5) If equipped with automatic transmission, slide
transmission cooler tube bracket forward on tubes far
enough for starter motor to be removed from lower
mounting stud.
(6) Lower starter motor from front transmission
housing far enough to access and remove nut secur-
ing battery cable eyelet to starter solenoid stud.
Always support starter motor during this process. Do
not let starter motor hang from wire harness.
(7) Remove solenoid wire solenoid terminal stud.
(8) Disconnect battery cable solenoid wire from
receptacle on starter solenoid.
(9) Remove starter motor from transmission hous-
ing.
4.7L With Automatic Transmission
(1) Disconnect and isolate negative battery cable.
(2) Raise and support vehicle.
(3) Remove bolt and washer (rearward facing)
securing starter motor to the transmission housing
(Fig. 13).
Fig. 11 Starter Motor Remove/Install - 2.5L Engine
1 - SCREW AND WASHER
2 - EYELET TERMINAL
3 - NUT
4 - BATTERY POSITIVE CABLE WIRE HARNESS
5 - WIRE HARNESS CONNECTOR
6 - SCREW AND WASHER
7 - STARTER MOTOR
Fig. 12 Starter Motor Remove/Install - All 3.9L/5.9L,
or 4.7L Engine with Man. Trans.
1 - EYELET TERMINAL
2 - NUT
3 - BRACKET
4 - STUD
5 - STARTER MOTOR
6 - LOCK WASHER
7 - WIRE HARNESS CONNECTOR
8 - NUT
9 - SCREW AND WASHER
Fig. 13 Starter Motor Remove/Install - 4.7L Engine
with Automatic Transmission
1 - EYELET TERMINAL
2 - NUT
3 - SCREW AND WASHER (2)
4 - STARTER MOTOR
5 - WIRE HARNESS CONNECTOR
AN
STARTING
8F - 37
STARTER MOTOR (Continued)
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