Starter woes

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Bl1zzard

Bl1zzard

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Hey there,

1974 Dodge Dart 360LA 902 transmission.

Original starter crapped out (not bad for 50 years of service), bench tested and it barely spun but got damn hot. Bought a new PowerMaster and just installed it today. Loud click of the gear popping out but nothing else, no clicking , grinding, humming, anything. Tried manually cranking the engine with a socket thinking maybe I need to align something but same result. Is it possible that it's just jamming up against the flywheel and not syncing? I read about shims but the old one didn't have shims. Thoughts, suggestions? It's my first starter replacement.
 
Mine did that intermittently. I added some shims and it has worked perfectly since then. I just used a couple flat washers, probably about .0625 thick.
 
SSG_Karg said:
Mine did that intermittently. I added some shims and it has worked perfectly since then. I just used a couple flat washers, probably about .0625 thick.
Click to expand...
So, I added 2X .0625 thick washers. Same result, loud click no crank. More washers, did you use 2 per bolt? For a total of .125 or 1/8"?
 
Bl1zzard said:
So, I added 2X .0625 thick washers. Same result, loud click no crank. More washers, did you use 2 per bolt? For a total of .125 or 1/8"?
Click to expand...
No, I only used one washer per bolt.
Try loosening the bolts and “pushing” the starter away from the flywheel to gain a little more clearance then tighten.
 
Make sure the thinner brown wire from the starter is firmly plugged into the terminal on the starter relay on the firewall.
I also never had to shim any starter, and a powermaster is not a low buck dimensions be damned type of starter.
You can also test the relay by jumping the two connectors on the starter with a remote start switch
 
Could be low battery voltage, poor/corroded/loose battery connections. Odd that two starters failed...
 
Bewy said:
Could be low battery voltage, poor/corroded/loose battery connections. Odd that two starters failed...
Click to expand...
Battery is new and fully charged, cables are all new, just rebuilt the engine a few years ago and made damn sure all the electrical was refreshed too. But thanks for the advice.
 
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4eighteener said:
Make sure the thinner brown wire from the starter is firmly plugged into the terminal on the starter relay on the firewall.
I also never had to shim any starter, and a powermaster is not a low buck dimensions be damned type of starter.
You can also test the relay by jumping the two connectors on the starter with a remote start switch
Click to expand...
The bendix is definitely popping out and into the flywheel, but it's jamming up and not syncing. I didn't think I'd have to shim anything, but the instructions that came with the starter indicate otherwise. Shimming didn't help anyway. I spent the rest of my Sunday pulling off the headers and yanking it out. I'll bench test it to see if it's working properly, but I'm pretty sure it is. With the rest of my Sunday, I took apart the old starter, cleaned it, measured the resistance on every connection, regreased the bearings and reassembled it. It spun up nicely after that, it may be going back in instead.
 
Not trying to insult you, but double check the part number of the starter. Could be wrong one? Hope you get it sorted out.
 
Bl1zzard said:
The bendix is definitely popping out and into the flywheel, but it's jamming up and not syncing. I didn't think I'd have to shim anything, but the instructions that came with the starter indicate otherwise. Shimming didn't help anyway. I spent the rest of my Sunday pulling off the headers and yanking it out. I'll bench test it to see if it's working properly, but I'm pretty sure it is. With the rest of my Sunday, I took apart the old starter, cleaned it, measured the resistance on every connection, regreased the bearings and reassembled it. It spun up nicely after that, it may be going back in instead.
Click to expand...
I feel for you having done that lately myself, hence my suggestion about the brown wire to the relay. That was my issue. I replaced both starter terminals and the battery terminal, and either never hooked the wire up to the relay, or knocked it off with climbing around the engine compartment.
Anyway, after removing the starter twice I decided to test it on the car not installed and finally found the issue.
Good luck! Like I said, I feel for you
 

Sorry no bench test yet guys. I work during the week and am too tired to head out to the garage at night (getting old). It won't be until the weekend so cool your jets eh? ;-) The article in post #14 from @furrystump has me thinking though. The only thing we changed this winter was to add bigger fuel lines and, in the process, an electric fuel pump. I'm now wondering if there is a voltage drop problem. That wouldn't show up on a bench test because I'm connecting directly to the battery via booster cables, nothing else in circuit. Again, you'll all have to wait until the weekend though, sorry guys. Thanks for all the advice and support though, that's why I keep coming back here when I run into a challenge.
 
I’m so nervous about bad grounds, I have a total of 4 battery cable sized eyelet cables from the motor to the chassis and battery. I hate electrical issues!!!!
 
Funny enough. I know someone who has chased starter issues and I’m pretty sure he doesn’t have the stud. Neither do I, no issues for me, but running a Dakota starter for 6-7 years with no issues.
 
Yea I’d get my money back for the power master thing, and go get a parts store magnum starter. They work awesome and are cheap.
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So y'all got me fired up. When I got home I ran out to the garage before dinner and bench tested the new PowerMaster. It's DOA. The Bendix pops out but no spin at all. Lesson learned, bench test before install. Going to return it and use the old starter.
 
Bl1zzard said:
So y'all got me fired up. When I got home I ran out to the garage before dinner and bench tested the new PowerMaster. It's DOA. The Bendix pops out but no spin at all. Lesson learned, bench test before install. Going to return it and use the old starter.
Click to expand...
FYI I looked up the specs on that PM and it’s hardly any different than a magnum mini starter. I get mine for a 2001 dodge ram 2500 with a 5.9 and they work fantastic.
 
Probably the same starter, both made in China & put in different boxes. Friend bought a MSD starter for his Pontiac & I compared it side by side with a no-brand Chinese one I bought. Both had the same MSD 'red' paint but the MSD was about 3 times the price....
 
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