Ram Truck 1500, 2500 & 3500 (2006-2008)

Starter

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Precautions



Always disconnect the negative battery cable before servicing the starter. Battery voltage is always present at the large (B) terminal on the solenoid. When removing the starter motor, be prepared to support its weight after the last bolt is removed, because the starter motor is a very heavy component.

Never operate the starter for more than 30 seconds at a time. Too much cranking will cause the starter motor to overheat, causing permanent damage. Allow the starter to cool for at least two minutes between starting attempts.

Removal & Installation



3.7L & 4.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.


    NOTE
    On the 3.7L engine, the left side exhaust pipe and front driveshaft must be disconnected.



    Negative battery cable
     



    Starter mounting bolts
     



    Starter solenoid harness connections
     
    Starter
     

  4.  

To install:

  1. Connect the starter solenoid wiring connectors.
  2.  
  3. Install the starter and torque the bolts to 40 ft. lbs. (54 Nm).
  4.  
  5. On the 3.7L engine, the left side exhaust pipe and front driveshaft
  6.  
  7. Install the negative battery cable and check for proper operation.
  8.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Depending on drivetrain configuration, a support bracket may be used.



    Negative battery cable
     



    Starter mounting bolts
     
    Starter solenoid harness connections
     
    Starter
     

  4.  

To install:

  1. Connect the starter solenoid wiring connectors.
  2.  
  3. Install the starter and torque the bolts to 50 ft. lbs. (68 Nm).
  4.  
  5. Install the negative battery cable and check for proper operation.
  6.  

5.9L Diesel Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate both negative battery cables at both batteries.
  4.  
  5. Raise and support vehicle.
  6.  
  7. Remove 3 starter mounting bolts .
  8.  
  9. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process. Do not let starter motor hang from wire harness.
  10.  
  11. Tilt nose downwards and lower starter motor far enough to access and remove nuts securing starter wiring harness to starter . Do not let starter motor hang from wire harness.
    NOTE
    Note: Certain diesel engines use an aluminum spacer . Note position and orientation of spacer before removal.

  12.  
  13. Remove the starter motor from the engine.

    Click image to see an enlarged view

    Fig. Starter mounting bolts (1), starter motor (2), and spacer plate (3)

  14.  

To install:

  1. (If equipped). Position and hold aluminum spacer to rear of starter while positioning starter to engine.
  2.  
  3. Connect solenoid wire to starter motor. Tighten nut to 4.4 ft. lbs. (6 Nm).
  4.  
  5. Position the battery cable to starter stud. Install and tighten battery cable nut to 10.3 ft. lbs. (14 Nm).
    NOTE
    Do not allow starter motor to hang from wire harness.

  6.  
  7. Position the starter motor to transmission.
  8.  
  9. If equipped with automatic transmission, slide cooler tube bracket into position.
  10.  
  11. Install and tighten 3 starter mounting bolts to 32 ft. lbs. (43 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Connect both negative battery cables to both batteries.
  16.  

6.7L Diesel Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate both negative battery cables at both batteries.
  4.  
  5. Raise and support vehicle.
  6.  
  7. Disconnect the solenoid electrical connector.
  8.  
  9. Remove the battery cable mounting nut.
  10.  
  11. Remove the battery cable from stud.
  12.  
  13. Remove three starter mounting bolts.
  14.  
  15. Remove the starter motor from engine.
  16.  

To install:

  1. Connect solenoid wire to starter motor. Tighten nut to 4.4 ft. lbs. (6 Nm).
  2.  
  3. Position the battery cable to starter stud. Install and tighten battery cable nut to 10.3 ft. lbs. (14 Nm).
    NOTE
    Do not allow starter motor to hang from wire harness.

  4.  
  5. Position the starter motor to transmission.
  6.  
  7. Install and tighten 3 starter mounting bolts to 32 ft. lbs. (43 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect both negative battery cables to both batteries.
  12.  

Testing & Troubleshooting



Any troubleshooting of the starting system should start with checks of the following components:



Battery condition
 
Wiring and connections at the battery, starter motor and solenoid
 
Starter relay
 
Wiring at switches: clutch pedal (if equipped), Park/Neutral position switch (if auto), ignition switch
 


CAUTION
Before performing any of the tests below, make sure that the engine will not start accidentally by disconnecting and isolating the ignition coil wire (gasoline engines) or unplugging the fuel shutdown solenoid wire harness (diesels). Place the transmission in Neutral (manual trans.) or Park (auto trans.), parking brake applied.

  1. Ensure that the battery is in good condition and fully charged. Simply checking for voltage across the terminals will not indicate battery condition. A load test is required. This requires special equipment, but a local garage or parts store may be able to help. Check the battery and clean the connections as follows:
    1. If the battery cells have removable caps, check the water level. Add distilled water if low. Load test the battery and charge if necessary.
    2.  
    3. Remove the cables and clean them with a wire brush. Reconnect the cables.
    4.  
    5. Check for voltage across and battery posts and across the clamps to ensure that clamp connections are making good contact.
    6.  

  2.  
  3. On manual trans. models, disconnect the clutch position switch and connect a jumper across the harness connector to simulate depressing the clutch pedal.
  4.  
  5. Connect the voltmeter leads to the battery positive terminal and the starter solenoid battery cable stud. Turn the ignition switch to START and hold it there. If the meter reads above 0.2v, suspect bad contact at the solenoid battery cable stud.
  6.  
  7. Connect the voltmeter leads to the battery negative terminal and a good ground on the engine. Turn the ignition switch to START and hold it there. If the meter reads above 0.2v, suspect bad connections of the battery negative cable or internal corrosion of the cable.
  8.  
  9. Connect the positive lead of the voltmeter to the starter motor housing and the negative meter lead to the battery's negative terminal. Turn the ignition switch to START and hold it there. If the meter reads above 0.2v, suspect poor starter-to-engine ground.
  10.  
  11. If the above tests do not reveal the cause of the problem, proceed to component tests, following.

    Click image to see an enlarged view

    Fig. On diesels, disconnect the fuel shutdown solenoid before doing any work on the starter motor



    Click image to see an enlarged view

    Fig. Checking for voltage drop across the battery clamps



    Click image to see an enlarged view

    Fig. Testing the battery positive cable voltage drop



    Click image to see an enlarged view

    Fig. Testing for ground circuit voltage drop



    Click image to see an enlarged view

    Fig. Checking starter ground

  12.  

Starter Solenoid

Certain vehicles with certain engines may require starter motor removal for the following test.

  1. If necessary, remove starter motor from vehicle. Refer to starter motor removal and installation.
  2.  
  3. Disconnect solenoid connector wiring from starter motor.
  4.  
  5. Check for continuity between solenoid terminal (2) and solenoid case (3). There should be continuity.
  6.  
  7. If not OK, replace faulty starter motor assembly.

    Click image to see an enlarged view

    Fig. Starter solenoid continuity testing procedure

  8.  

 
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