LarryB's Dodge starting problems solved here.

LarryB's

Dodge Cummins Ram truck

Starting problems solved here!

START HERE >>> Frequently Asked starter Questions

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Part#R90SS $34.95 Solenoid rebuild kit, contains 2 SuperSize contacts and 1 plunger for Cummins. Printed instructions included with this kit

Super Size Starter contacts have approximately 90% more contact area than stock. Designed to carry twice the voltage load for easier starting and last years longer. Our Super Contacts Fit perfectly and are for replacement of sticking and clicking stock starter contacts in 1989 to 2007 Cummins powered Dodge Ram trucks. (for V10 engine click here) Is your starter clicking a few times and won't crank? Or worse yet, sticking on? It's very likely worn solenoid contacts. These trucks use a very well built gear reduction starter. Your starter contains two contacts that are usually the only parts in these starters that cause any problems. Usually only one contact gets badly burned but we recommend replacing both contacts and the plunger while you're in there. Printed INSTALL INSTRUCTIONS are also included with all contacts. More info? CLICK here!!!! Here is an exploded view of the solenoid and parts.

New Nippon OEM Starter, not a rebuilt.

These New OEM replacement starters for Dodge/Cummins come with SuperSize contacts installed. We no longer supply aftermarket starters because of unreliable quality from the manufacturers. We now only carry genuine NEW NIPPON starters. The exact same starter that came with your truck except we have installed supercontacts. For the person who wants to make absolutely sure it's done right. Don't install a cheap starter! You get what you pay for.

(frequently asked starter questions) E-mail me for info on other starters

Replacement brushes. Denso starters use a very good, long lasting brush material. It is common for these brushes to last 300,000 miles without a problem, although sometimes in trucks used off road water intrusion can cause early wear. Common symptoms are slow cranking but check your batteries and cables first. Brushes should be replaced when there is less than 2mm clearance between pigtail and brush holder, in other words if the brush can only move 2mm more toward the commutator when wearing. These brushes require soldering to brush plate and field wires (Install instructions)

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Part#8207 $24.75 Set (4) brushes. Some soldering required, fit starters on 1994-2002 Dodge Ram with Cummins engine

Part#8203 $39.00 New Brush plate with ground brushes installed. , 1994-2002 Dodge Ram with Cummins. (some soldering required)

Battery side stud replacement kit. Click pic for larger view

Occasionally a loose battery cable at the starter can cause arcing/corrosion and the stud may be damaged causing difficult removal. I have seen case where the only way to remove the cable is by cutting the stud off with a hacksaw. Your is probably fine, but if not, this is what you need. Genuine parts.

Part#2791 $19.95 ..Includes copper stud with knurl for battery cable connection, washer, nut, O-ring and all insulators.

10mm, 12 point combination wrench for starter removal

You probably already have one of these but if not you'll need one to remove the starter. Dodge used special high strength bolts to attach the starter to the engine and they have 10mm, 12pt heads. You can use a socket on the two lower bolts but the top bolt needs a wrench. This top bolt can be an SOB to get loose. The bolts are tight and there's not much room to work. I have found the best way is to put the wrench on the bolt then use a piece of wood and a small jack to lift up on the end of the wrench to break the bolt loose.

70amp 2, small.jpg (8217 bytes) Fuel Shutoff relay.

Part# SS70A $19.90 New replacement 70 amp fuel shut-off relay.

This 70amp relay activates the fuel solenoid on years 94-98.5 12valve. If this relay is bad your engine will crank fine but will not start because the fuel is not getting to the engine. I always carry a spare in my truck. Also check your blue wire fusible link (available below) at the pos battery terminal before replacing this relay, if corroded or burned it will cause the same symptoms. starter wiring diagram RELAY LOCATION

This relay is physically different than stock, the mounting is slightly different. Electrically it is identical. Some stock relays are a double relay that includes the fuel heater relay. You can unplug the fuel shutoff side only and install this relay to avoid having to buying the double relay.

Fuel Shut-off solenoid,

In stock now! for immediate shipment!!!!!

This is the part that gets destroyed if your starter sticks on. (see location) If yours burned up you should replace the starter contacts or install a Larry'B's Solenoid-Saver Diode before replacement. If the plunger stays up with the key on but won't pull up when you crank the starter, check your RELAY and blue wire first. Your solenoid may be fine.

Part# FS20, $197.90 New OEM upgrade replacement fuel shut-off solenoid for years 94-98.5, 12valve. This is the exact heavy duty upgrade replacement part made by the OEM. No silly wiring adapter needed. Also comes with new brackets, screws and levers. About a 5 min job to remove and replace. Compare this price to the dealer, you'll be surprised. Exact same part. (adjustment procedure) No wiring adapter needed! This is the correct part! We also strongly recommend installing a Solenoid-Saver Diode so you won't have to replace this part again.

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Fuel Solenoid Replacement boot only

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Part# FS21 boot only, $26.75 Fuel Solenoid Replacement boot only. New replacement fuel boot only for shut-off solenoid above. This is the exact replacement part made by the OEM. It keeps the solenoid plunger and spring clean to prevent binding. It also holds the plunger in the solenoid. About a 5 min job to remove and replace. I know this is a lot of money for a piece of rubber but it is a patented design, hard to get and it's less expensive than a new solenoid.

Replacement BLUE WIRE (Fusible Link)

This replacement fusible link is the protection for the power supply to your fuel shutoff solenoid. It's a 65 amp inline fuse that is connected to the driver's side battery at the positive terminal bolt. Sometimes the lug on the end or the wire itself gets corroded and will cause symptoms that are the same as a bad fuel shutoff solenoid. This link has the connectors installed and comes with a piece of heat shrink tubing to complete the repair right. Some 98's have a fuse in the fuse box instead of this type of protection.

Super Safe Quick Disconnect battery bolts.

Super Safe battery terminal bolts.JPG (19848 bytes) All Stainless steel with cam action lever. Very high quality and they work like they are supposed to.

Part#SSQD $24.00pr, 1 red and 1 black. .

Fuel hose replacement kit. For replacement of the fuel hoses that run from the engine to the frame on 12 valve, 1994-1998.5 Dodge/Cummins trucks. This kit includes 28" each of both sizes needed for the feed and return lines. This is not just standard autoparts hose. its top quality Trident #365 marine USCG approved hose. Quality Stainless Steel hose clamps included. When your old hoses start leaking you may not even be able to see it. They start leaking air into the injection system causing hard or no starting. Especially if parked facing up hill with low fuel. Kit includes 28" each of 5/16"ID and 3/8"ID hose and 4 stainless hoseclamps.

This hose is also available in any length by the foot, just click here!