Okay, I blew my first starter relay fuse about 2 months ago. I replaced it after searching for a day on the problem and all has been fine since. Now it has happened on 3 occasions in the past week. I replaced the starter relay with a new one, and just cant figure out why it keeps blowing them. All I do is replace the fuse and it fires off. I've gotten pretty fast on replacing them, and keep some in my console handy. Thanks for any help, George

 

I'd try replacing your starter contacts or the whole starter. Check my pics for what back contact look like.


Call these guys and ask them.
http://www.fostertruck.com/dodge/default.htm

 

So this could be shorting it out?

 

Bad starter contacts on a 24v will blow the fuse! I know ...it did it on my wifes 2k. I had the new starter contacts from LarryB in my tool box at home ready to be installed. When the truck didnt start that when I dropped the starter and found the contacts were worn down to nearly nothing..(just one)..Once the contacts and fuse was replaced...truck fired right up..
I called and talked to Larry about this and he said yes...for some reason it put a heavier load on the fuse when the contacts are worn out.

Rick

 

Thanks folks, Ill put in an order today.

 

Let us know if it works. Pretty easy job. Make sure you disconnect BOTH batteries before you start to remove the starter. Don't ask me how I know that.

 

Worn contacts cause high resistance to electron flow and jack up the amp draw thereby blowing the fuse. Near dead batteries will also cause this.

 

I just replaced my starter with a napa life time guaranteed one. pulled it apart first and one contact was completely gone. It would just click some times and one time it wouldnt reliese after the motor started . I pulled it out then.
I wanted to just replace the contact but it was just easyer to get a hole new starter rather than tryng to track down and wait to get shipped a new contact.

 

Okay, I had it tested, and the amperage was randomly shooting up to 20-30 amps. Thats when it blows the fuses. I ended up getting a circut breaker put in place of the fuse, which could last a good while, and I picked up some contacts from another place. I was thinking about returning the contacts, because they ended up being about $30 and getting one of these or similar:

http://cgi.ebay.com/ebaymotors/94-20...spagenameZWDVW

Will this do? It's the same starter he tried to sell me for $250

 

It's your call. The contacts are bad so if you want to replace the whole starter you can. I'm not a big fan of the circuit breaker set up. If the circuit breaker fails (and they do) you'll have a fire. As for the e-Bay starter I'm sure it would be fine.

 

Its kinda expensive to replace the starter for $250 or what ever when you can get a set of heavy duty contacts for $45 or so. On LarryB's starter contacts there is 90% more area than on the stock contacts.
I replaced the plunger and contacts on my starter 60k ago and it works better than before..

Rick

 

I picked up the larger contacts here in town, so I'll just replace them. He said on the plunger, just clean it up with some sand paper. Thanks for all the help guys! I'd like to know how much $$ has been saved from this website through avoiding costly repairs.

 

Enough that I could quit work and live real nice

Rick