3.3 liter 96 intrepid denso starter rebuild - DodgeIntrepid.Net Forums - Dodge Intrepid, Concorde, 300m and Eagle Vision chat
 
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post #1 of 9 (permalink) Old 08-31-2006, 09:13 PM Thread Starter
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Smile 3.3 liter 96 intrepid denso starter rebuild

Starter motor reconditioning GUIDE

Dodge Intrepid 1996 V-6 cylinder 3.3 liter



copywrited by PSKi Enterprize 2007 at your own risk instructions :biggrinfl

Preamble:

I was driving some friends around town when I noticed that my inTrepid got a case of the "It won't start when I turn the key syndrome". I tried oiling the keyhole, new key, and checking the wiring under the hood andd in the ignition coloumn but to no avalile. This is a bad starter, its a Denso unit made in japan I found , one with a common complaint and a seemingly easy inexpensive fix. Other members have stated that the starter due to its nature as a low use high heavy build nature should last forever, I took this to heart. My starter should still be intrinsicly be good !.

The common complaint about this denso starter was in the selenoid box were a couple of copper contacts simply wear out from use . This is a simple and inexpensive fix .

I was surprised how easy the Denso starter are to do , if you can do your front rotors this is about the same.

To the Intrepid Lair !! :fun_66:

tools
15 mm wrench and wrench set
hand wrench
extensions
pliers
wire cutters

Parts


link to plunger # 35


the right one is number 35
and costs about $10.00



The selenoid contact is about $5.00 more and has 2 parts

Cost me about $40.00 cnd + taxes and shipping



some bearing greease
some shop rags


To remove the starter you can do it from the top port side of the car.
You need to be flexible and handy with a couple of 15 mm wrench types large and small.
Turn only about a 1/4 turn on each try and take your time , you can not rush this job.

Unbolt the three bolts that hold the starter in and then pull it out a bit. Then take your wrench and loosen and remove the wires to the battery and ground. Try not to break the ground wires.

Then I just jiggled the unit out from under the manifold ,
not bad now lets see if I can get it back in there



chewed up contact inside solenoid box


screw driver pointing out bad contact


The plunger sits inside this box and slides back and forth when the key is turned completing contact.




the plunger has a ball bearing at the end of it along with a spring to force it back after ignition --
don't lose em and put them back in proper sequence.




The contacts are press fit with serations on the fully copper bolts . Take your time to remove em and then place them properly to insert them.


Starter Solenoid Contacts Replacement
You will have to remove the starter from the vehicle.


Once you have it off you need to take the end cover off the solenoid, its best to use a 8mm wrench or socket. , really normal


Once the cover is off you can take out the plunger and spring. The plunger will look like this


You can then see inside the solenoid to the starter solenoid contacts.



Its the wear on these combined with the burned surface on the plunger that is causing those clicks when you go to start the engine.



The starter solenoid contacts shown are both new (bright) and old (dark). If you look closely you will see on the old one there is an area worn away on the flat surface that contacts the plunger. Its this extra distance that the plunger need to travel that caused the intermittent connection and the clicks.



Clean up the plunger as shown.


You need to take off the starter solenoid contacts from the large bolts on the starter case and "tap off the old starter solenoid contacts" from the bolts. You install the new starter solenoid contacts the same way. You will see that there are some insulators protecting bolts from the metal case. Its important not to forget to reinstall these the way they came off.
When finishing the insulation of the contacts make sure that they are sitting flat in the starter. If they are not, (and in tightening the lock bolts they can twist) the starter will click again after a couple of days.



Slowly put them in the old starter after rubbing all the contacts with steel brush and coating them in white lithium

that stuff has a nice kinda fragrance to it , errr oh well


all the piece fit then I had to replace the starter --- awwwwwrg what a pain , it has very little room in there
firstly before placing the starter back into the hole in the transmission replace the ground wire etc, bolt them back on and make sure that the starter cover plate is properly oriented before the starter is in place.

had to contort quite a bit and wrench a 1/4 turn at a time

including many wrench twists to get the 3 bolts back in

did the center one first then the top and finally the bottom

make sure to reconect the ground strap, its there for a reason

I could not torqued em in with my torque wrench as it won't fit in the maniforld space

So good and tight ==> really tight will have to do


then once I cleared the engine bay I tried a re-start

after a while of crankin ( it's working!!!) she fired and ran

Notonly that but now after about half a year the starter has never failed to start the engine even thorough the -35 C really cold weather we have here. The starter is ine its just those little copper contacts that wear away all too fast.



**

Last edited by 123456; 04-05-2007 at 08:40 AM.
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post #2 of 9 (permalink) Old 09-01-2006, 04:58 PM
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I'd like to know how you do. I have a 93 New Yorker with the 3.3 that the starter is going out just like my 94 did almost two years ago. I've been tempted to just rebuild the solenoid cause the reman starter on my Concorde was acting like it was gonna go again a few months ago.
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post #3 of 9 (permalink) Old 09-01-2006, 06:50 PM
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Great little foreign made parts aren't they? Mine went at 74K.
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post #4 of 9 (permalink) Old 09-15-2006, 12:03 PM Thread Starter
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Smile

FINALLY

got the plunger and the contacts yesterday in the mail from ebay..

Slowly put them in the old starter after rubbing all the contacts with steel wool and coating them in white lithium

that stuff has a nice kinda fragrance to it , errr oh well


all the piece fit then I had to replace the starter --- awwwwwrg what a pain , had to contort quite a bit and wrench a 1/4 turn at a time including wrench twists to get the 3 bolts back in

did the center one first then the top and finally the bottom

torqued em in tighe my t wrench won't fit in the maniforld space so i gues its tight enough


then once I cleared the engine bay I tried a re-start

after a while of crankin ( it's working!!!) she fired and ran


yahooo the fix is working and only $40 instead of a $400 job

couldn't be happier :gross_07:


its now march and its still working every time even after some -30C weather :fawkoff:

Last edited by 123456; 03-21-2007 at 06:45 PM.
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post #5 of 9 (permalink) Old 09-15-2006, 12:06 PM
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congrats, hopefully it will last.
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post #6 of 9 (permalink) Old 09-15-2006, 12:07 PM
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steel wool is a bad thing to use, no matter how careful you are in cleaning up, there will always be little steel particles left behind which will rust and mess up your contacts.

Better to use a non-metallic sandpaper of some kind.
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post #7 of 9 (permalink) Old 01-01-2007, 08:50 AM
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I know this is an old thread but I just replaced my plunger. I was having intermitten starting problems(usually in cold weather). I had replaced all battery cables, relays and cleaned ground straps with no luck. I read this thread and figured I would try. I order the plunger from http://www.nationsautoelectric.com/Nippondenso.html. Parts came quick and for $20 it should last. Its also very easy to change. I used electronic cleaner and a wire brush to clean all contacts and applied dielectric grease to them. Fired up strong!! 123456 THANKS FOR THE TIP.
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post #8 of 9 (permalink) Old 01-02-2007, 11:06 AM Thread Starter
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hi


just to make it clear---

I also replaced the selenoid contacts, for $5.00 more , to have all new contact surfaces

its 4 months later and it feels as good as new still
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post #9 of 9 (permalink) Old 01-02-2007, 03:03 PM
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I thought I had ordered the plunger and contacts but apparently didnt. With the holidays and everything I just didnt have a chance to get them. And with the weather getting cold I cant afford to be stranded in North Philly(not a friendly neighborhood). Anyway just wanted to say thanks for the tip, saved me a $100 for a shit rebuilt starter.
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