Dodge Durango (HB). Manual - part 262

STARTER

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.

2. Disconnect wire from solenoid field coil terminal.

3. Check for continuity between solenoid terminal (3)

and solenoid field coil terminal (2) with a continuity
tester (1). There should be continuity. If OK, go to
Step 4. If not OK, replace faulty starter motor
assembly.

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4. Check for continuity between solenoid terminal (1)

and solenoid case. There should be continuity. If
not OK, replace faulty starter motor assembly.

REMOVAL

3.7L / 4.7L With Manual Trans.

1. Disconnect and isolate negative battery cable.

2. Raise and support vehicle.

3. Note: If equipped with 4WD and certain transmis-

sions, 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.

4. Remove one bolt (9) and one nut (8) if equipped

with a manual transmission.

5. Move starter motor (5) 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.

6. Tilt nose downwards and lower starter motor far

enough to access and remove nut (2) that secures
battery positive cable wire harness connector eye-
let to solenoid battery terminal stud. Do not let
starter motor hang from wire harness.

7. Remove battery positive cable wire harness connector eyelet (1) from solenoid battery terminal stud.

8. Disconnect battery positive cable wire harness connector (7) from solenoid terminal connector receptacle.

9. Remove starter motor.

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STARTING

3.7L / 4.7L With Auto. Trans.

1. Disconnect and isolate negative battery cable.

2. Raise and support vehicle.

3. Note: If equipped with 4WD and certain transmis-

4. Remove two bolts (3) if equipped with an automatic

transmission.

5. Move starter motor (4) 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.

6. Tilt nose downwards and lower starter motor far

enough to access and remove nut (2) that secures
battery positive cable wire harness connector eye-
let (1) to solenoid battery terminal stud. Do not let
starter motor hang from wire harness.

7. Remove battery positive cable wire harness connector eyelet (5) from solenoid battery terminal stud.

8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle.

9. Remove starter motor.

5.7L V-8

1. Disconnect and isolate negative battery cable.

2. Raise and support vehicle.

3. Note: If equipped with 4WD and certain transmis-

4. Remove two mounting bolts (2).

5. Move starter motor towards front of vehicle far

enough for nose of starter pinion housing to clear
housing. Always support starter motor (1) during
this process, do not let starter motor hang from
wire harness.

6. Tilt nose downwards and lower starter motor far

enough to access and remove nut that secures
battery positive cable wire harness connector eye-
let to solenoid battery terminal stud. Do not let
starter motor hang from wire harness.

7. Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud.

8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle.

9. Remove starter motor.

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8F - 47

INSTALLATION

3.7L / 4.7L With Manual Trans.

1. Connect solenoid wire to starter motor (snaps on).

2. Position battery cable (1) to solenoid stud. Install

and tighten battery cable eyelet nut (2). Refer to
Torque Specifications. Do not allow starter motor to
hang from wire harness.

3. Position starter motor (5) to transmission.

4. Install and tighten lockwasher (6) nut (8) and bolt

(9). Refer to Torque Specifications.

5. Lower vehicle.

6. Connect negative battery cable.

3.7L / 4.7L With Auto. Trans.

1. Connect solenoid wire to starter motor (snaps on).

2. Position battery cable (1) to solenoid stud. Install

and tighten battery cable eyelet nut (2). Refer to
Torque Specifications. Do not allow starter motor to
hang from wire harness.

3. Position starter motor (4) to transmission.

4. If equipped with automatic transmission, slide

cooler tube bracket into position.

5. Install and tighten both bolts (3). Refer to Torque

Specifications.

6. Lower vehicle.

7. Connect negative battery cable.

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