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Starter fire :/

April 16, 2015, 03:29:55 pm

I am working on a 1978 Avco. A brand Foretravel bought out in the 1980s. The engine is a dodge 440.

Originally when you would turn the key it would just click really loud. After doing that a half dozen times it would crank and the engine would start.

I am working on this for a friend and he said it did that for a few years. I was doing some other work on the coach and had the same issue and then it just stopped clicking.

I removed the stater and bench tested it and I could only get it to click on the bench. The gear that engages the fly wheel would kick out but not spin.

I replaced the starter and it fired right up no problem. I started it about 10 times and had taken it on two 30 mile trips. After the second trip, I shut it off and it started right back up. About 10 mins later I went to start it again and it cranked really slow, maybe 4 revolutions but then stopped.

I thought it was a low battery. Charged it up over night and then got it to click a few times then nothing.

I grabbed another battery and hooked it to the coach with jumper cables. Still got no crank. I then went under the coach and found that the relay where the main starter wire connects had a loose nut. I tightened it up and it cranked and started. I shut it off and it started right up a second time.

I then disconnected the jumper battery to take the coach for a test drive. Went to start it for the test run and it cranked slowly. I tried that twice before smelling smoke. Looked under the coach and white smoke was pouring out of the new starter.

I got the battery disconnected in time not to really burn up the whole coach. The cable from the relay is fried as well as the starter but the rest looks undamaged.

Can anyone tell me what went wrong here? and what steps to take to fix it?

I am not very familiar with this dodge relay system. :/ Is there a retrofit that might be a better option?
Thanks so much Tony

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Re: Starter fire :/

Reply #1 – April 16, 2015, 04:35:55 pm

Generally low voltage can fry a motor, because it draws more current than the windings are designed for.  With that in mind, any number of things can cause low voltage from a low battery, damaged cable terminal ends, too small a cable, loose connections, etc.
Starter is probably under warranty, so replace it.
Add a simple starter solenoid may help by running a good cable from battery to solenoid and another good cable to starter.  Wire that triggered starter before now will go to new solenoid small terminal.  If solenoid has two small terminals run a ground wire to other small terminal.  Solenoids shorten current bath from battery to starter.  Make sure battery end terminals (pos & neg) are good and clean.
Too many starts without letting starter cool or cranking too long each time, with bad cable connections may have taken its toll on the new starter.  Also rebuilt starters are notorious for failing because some old worn components are reused.
Dodge 440 is a good engine.  Make sure starter is designed for 440.

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Re: Starter fire :/

Reply #2 – April 16, 2015, 05:30:36 pm

 Most motorhomes that had the dodge engine used the 440-3, it is different from the standard 440.  When getting parts, especially heads, valves, gaskets etc be sure you spec 440-3.  FT used the 440-3 in the Travco's that they built.
Gary B

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Re: Starter fire :/

Reply #3 – April 16, 2015, 09:20:24 pm

Low cranking battery power caused the starters to sling lead.  That's all I remember from a 30 year ago James t mention

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