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Old 04-08-2006
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Default Cummins Starter Removal and Install

This will be a comprehensive view of a starter removal and install.

Caution : Always use care when working on your vehicle! Do not disconnect electrical cables while engine is running !

Warning : Before starting work, be sure the vehicle is in Park or in Neutral (for manual transmissions). The parking brake should be set and wheels chocks should be used under two tires .

Tools Needed

This a is a general list and most will be required on all Cummins starters from 89 to present.

10mm combination wrench/ 12 point
12mm combination wrench
13mm combination wrench
14mm combination wrench
15mm combination wrench
1/2 combination wrench
9/16 combination wrench
3/8's drive rachet
1/4 drive rachet
3" 3/8th extension
3" 1/4 extension
1/4 drive 12mm 12 point socket
3/8 drive 12mm 12 point socket


Removal:

1 Make sure the the rest of the electrical system is in good working order.

Check to make sure the battery is charged to a minimum of 12.5 volts . If not charge the battery and load test it at a local auto store or repair facility. Corroded /loose connections ,spliced on cable terminals are a common source of problems . Replace bad cables and clean all corrosion from the cable ends.

2 Disconnect the - negitive battery cable FIRST , failure to do so can result in a voltage shock to the ECM and PCM.

3 Remove the small starter lead ,it is a spade connector and you can use a small screwdriver to and push in and release the tab and gently pull out the connector. Or you may the 8mm nut for which case a wrench or socket may be used.

4 Remove the + positive cable from the starter .

5 Remove the mounting bolts or hardware and remove the starter from the vehicle.

6 Make sure you have the correct starter ,physically put both starters beside each other and note connections and mounting holes. Nothings more aggrivating than having to go to the parts store more than once .

Installation

One of the most common unchecked item is the flywheel or the flexplate for wear and tear. Look for worn or missing teeth . If one or the other is badly worn then replace it . Failure to do so will only wear the new starer out . Obviously if you are on the side of the road ,the main concern is to get home or to a repair facility.

7 Mounting the starter . Install the starter into the bell housing and install all bolts by finger, then tighten bolts to 45 to 55 LBS.

8 Install the electrical connections back on the starter in the reverse fashion as mentioned above in steps 3 and 4.

9 Reconnect the battery - negitive cable and start the motor. Start the vehicle 3 or 4 times to be sure if the starter is working properly and does not produce any grinding noise . If you have a grinding noise the starer may not be fully seated into the bell housing . This is easy to do in a Cummins.

Congratulations now that was easy. [img]/forum/images/%%GRAEMLIN_URL%%/Lecture.gif[/img]

For troubleshooting see TROUBLE SHOOTING THREAD.
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