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July 7, 2013

Dodge Caravan NipponDenso Starter Motor Contact Repair

I’ve now seen the same starter motor failure in three different vehicles, a 1996 Plymouth Vogager (same as Chrysler Town and Country or Dodge Caravan), 1988 Toyota van, and 1987 Toyota Tercel, over the past 15 years, in what looks to be the same model starter motor. The motor appears to be made by NipponDenso. Essentially, the copper contacts inside the high current switch that turns the motor on erode (possibly by spark erosion) to the point that contact across them is no longer made by a solenoid-driven plunger, and as a result the starter motor gets no power and won’t crank the engine. Typically, these contacts can be easily and cheaply replaced. Here’s how I did this repair in my 1996 Plymouth Grand Voyager LE (3.8L V6) (more…)

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