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Starting Problem, Electric
Old 10-25-2009, 02:08 AM   #1 (permalink)
Matt42
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Join Date: Feb 2001
Location: Glendale, AZ USA
Posts: 869
Question Starting Problem, Electric

I have a similar, maybe the same, starting problem, with a twist. Here goes.
Truck:
=1996 49 state 5 speed 4x4.
=Daily driver?
no.
=Last driven?
90 days ago. (Was working out of state, etc.)
=Miles on truck:
75K, 10 miles/day stop & go, many starts.
=Weather?
Dry, warm, 80 to 115F
=Symptom?
Wait to start, hear click, no start. Multiple repeats: no click, no start.
=Swapping relays made no difference.
=Do lights dim when trying to start?
No
=Batteries?
Dekka AGM, new, OK.
=Voltage at starter, big wire:
12 V
=voltage at solenoid--brown wire:
12 V when ignition turned on
=voltage at solenoid when ignition turned off:
12 v after trying to start (yes, I checked twice!)
=Pulled starter relay and voltage at solenoid went to zero.
Did not recheck after putting relay back in. Should have. (insert dope slap here.)
=Starter solenoid contacts replaced in 05 or 06 with Larry B's original, not the supers.
=So I removed the starter
Works OK with no load.
Had load tested this evening at Checker. Failed three tries.

If it weren't for the very odd condition of power to the brown wire staying on with the ignition switch out of the start position, I'd just chalk this up to an old starter that's had hard city use. But this is the most vexing starter problem I've ever seen. Any ideas? I am flummoxed and it ain't pretty. Could that odd condition be due to welded solenoid contacts?

Thanks y'all and it's nice to be back.
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1996 Cummins 2500 4wd CC 5sp., 2001 PT Cruiser Touring, 2004 PT Cruiser Base, 2007 Town & Country Touring.

Last edited by Matt42; 10-25-2009 at 02:53 AM.. Reason: Added bit about swapping relays making no difference.
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