4th Starter for an '09

I had one that was eating starters at a ridiculous rate, something like 4 starters in 2 years. So I decided to dig and figure out why.

I tested starter voltage drop at the battery terminals, then at the starter. I don’t have the exact numbers right now but it was about .9v lower at the starter. So the positive cable had developed enough resistance from being old to cause problems. The starter had a sandpaper sound.

So I replaced the positive battery cable. Retested, the voltage drop difference was significantly better, no more sandpaper noise. It’s been over a year and a half, no issues since.

 

I'll make a point to measure voltage drop of all the components/wiring in the path during cranking to see if I can locate a problem. I have lots of experience doing that on aircraft and my other vehicles.

 

Voltage drop tests are great for checking cables/connections without getting dirty

 

I found my notes on this repair:

Starter voltage drop test at battery 9.67, at starter 8.87. Replaced positive battery cable, retest voltage drop at the starter, now only .23v, which is significantly better than .80v.

I know 9.67v is considered a fail. I didn't replace the battery at the time because it was weak from them repeatedly trying to start it. The next time I saw it, it tested good. But 10 months later I ended up replacing the battery, cranking slow, failed testing.

 

Just to clarify your process (google fu shows a couple of ways to do a voltage drop test).

Did you use a multimeter set to DC and make contact at the battery end with one probe and the starter end of the cable with the other probe? Of you checked the volts at the battery (9.67v) and then check the voltage at the starter (8.87v) and subtract?

My truck has been slow to start the last few times. The battery is relatively new (~14 months, Duracell 24F AGM), the weather has been cold, and the truck doesn't get driven as much as it did when I drove to an office every day. My first thought was that the copper contacts in the starter were getting worn down and that was causing the slow starts. Of course, it could be the battery (which has a 2 year full replacement warranty), but I'm thinking I'd like to test the cables.

Truck is a 2011 (that was purchased at the end of 2010) DCSB TRD Sport w/ tow package. Currently sitting at 178k miles.

 

First test starter voltage drop test at the positive and negative battery terminals, multi meter set to dc volts. Second test negative lead on negative battery terminal, positive lead on the starter fat positive cable. My meter has peak high hold and peak low hold, so I set it for peak low hold. Subtract, that'll give you what you're losing in the positive battery cable.

 

Yes that was a common issue with the early reduction starters actually have a couple in my tool box. The newer ones are pretty much bullet proof.

 

Jimmy - what was your mileage when you did the the contacts ? I have 150k - would it be good preventative maintenance ? Thanks for any reply.

 

My 2012 needed contacts in 2016...
The biggest cause of wear is a lot of starts.... more startups = more wear.

 

Mileage doesn't factor into the wear of the contacts it is more a function of the number of startups = more wear and tear on the contacts. It wouldn't hurt to have a new set ready to go for when the time is right you're ready.

https://www.nationsstarteralternator.com/Starter-Rebuild-Kits-s/37.htm

You should have plenty of warning, it doesn't usually go directly to fail mode.

Usually what happens is it would occasionally click and no starter action then after a cycle or two it worked. This continued to worsen until it would take 4 or 6 key cycles most of the time.

 

"You should have plenty of warning" That's good to know. You are extremely knowledgeable - how did that happen ? I follow a lot of your posts. Thanks for the reply.

 

Reman units from the dealer?

 

All were remanufactured OEM units from O'Reilly.

 

I'm old and was poor when I was young and had to figure a lot out by trial and error. Lots of errors! 50years of work experience 20 USN and 30 in the Automotive Automated Production as an electronics technician.

 

Thanks for the reply Jimmy - impressive. I have 155K - when I had starter problems on other vehicles years ago I hit the solenoid with a hammer and it started - do you think I should replace the SOLENOID and CONTACTS as preventative maintenance or just wait til there is a problem - some guys are posting a lot more miles then I have with no problem. Thanks again for sharing all your expertise .

 

I would wait for the start of issues as it starts slow and gradually gets worse as time goes on.

That being said you should do what makes you feel good about it. It is a fairly quick and inexpensive job. ( see Video ).

 

If it ain't broke, don't fix it.

 

Thanks Jimmy

Thanks Jimmy