Mopar R8080460AB Engine Starter

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First, check the following items: a) Make sure the battery cable clamps, where they connect to the battery, are clean and tight. b) Check the condition of the battery cables. Replace any defective battery cables with new parts. c) Test the condition of the battery. If it does not pass all the tests, replace it with a new battery. d) Check the starter motor wiring and connections. e) Check the starter motor mounting bolts for tightness. f) Check the related fuses in the engine compartment fuse box. If they're blown, determine the cause and repair the circuit. g) Check the ignition switch circuit for correct operation. h) Check the starter relay. i) Check the operation of the Transmission Range (TR) sensor. This system must operate correctly to provide battery voltage to the starter solenoid.

Begin by disconnecting the cable(s) from the negative battery terminal(s). Raise the vehicle and support it securely on jackstands. On certain models with 4WD and specific transmissions, there may be a support bracket blocking access to the lower starter mounting bolt. If present, remove the support bracket bolts and pry it aside. Remove the heat shield, if equipped, from the starter motor. Next, remove the nut securing the battery cable to the terminal stud on the starter solenoid and disconnect the cable from the terminal stud. Disconnect the electrical connector from the spade terminal on the solenoid. On models with a manual transmission, remove the starter mounting bolt and nut. On models with an automatic transmission, remove the two starter mounting bolts. Move the starter motor towards the front of the vehicle until the nose of the starter pinion housing clears the transmission bellhousing. Tilt the nose down and lower the starter to access the wiring connectors more easily. Finally, disconnect the battery cable and electrical connector from the terminals on the starter motor solenoid and remove the starter. For HEMI engines, follow a similar process, but also remove the two starter motor mounting bolts. For diesel engines, disconnect the wiring harness and battery cable from the starter, remove the three starter mounting bolts, and then remove the starter.

Remove and bench test the starter motor assembly, checking the solenoid's functionality. If the pinion drive extends but does not rotate, the solenoid is operational but the starter motor is defective. If there is no movement but the solenoid clicks, both the solenoid and starter motor may be defective. If the solenoid plunger extends and rotates the pinion drive, the starter assembly is functioning correctly.

Loosen the lug nuts on the left front wheel. Raise the vehicle and place it securely on jackstands. Remove the wheel. Remove the splash shield from the left front wheel housing. Remove the starter heat shield and fasteners, if equipped. Disconnect the battery cable and electrical connector from the terminals on the starter motor solenoid. Remove the two starter motor mounting bolts and remove the starter motor assembly.