Starter

Remove and replace the starter motor on a 2007 Ram 3500 with 5.9L Cummins diesel engine, including battery disconnect, heat shield removal if equipped, and proper electrical connections.

Warnings

Tools required

Parts

• Starter motor × 1 — Use OEM specification or quality aftermarket
• Heat shield gasket or bolts × 1 — If damaged during removal

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Allow engine to cool if recently operated
4. If needed for better access, raise front of vehicle and support on jack stands
5. Spray starter mounting bolts and electrical connections with penetrating oil if visible corrosion present

Procedure

1. 1

   Remove heat shield if equipped
   Locate the heat shield covering the starter motor on the driver side of the engine block. Remove the heat shield bolts and set aside the shield. Not all models have this shield installed.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect starter solenoid wiring
   Locate the two electrical connections on the starter solenoid. Remove the nut securing the B+ cable (large main positive cable from battery) to the solenoid stud. Disconnect the smaller trigger wire connector by pulling straight off. Support cables away from starter.
   ⚠Do not allow B+ cable to contact ground or other metal components - verify battery is disconnected
   Torque spec

   Starter Solenoid Nut12 Nm (9 lb-ft)
3. 3

   Support starter motor
   Position yourself to support the weight of the starter motor. The starter is heavy and will drop when the second bolt is removed. Have a clear path to lower the starter out from between the engine block and frame rail.
   ⚠Starter weighs 15-20 lbs and removal space is confined - maintain secure grip throughout removal
4. 4

   Remove upper starter mounting bolt
   Using a socket and extension, remove the upper starter mounting bolt. This bolt threads into the bellhousing. The bolt may be longer than expected and require a long extension to fully extract. Keep track of bolt length and any spacers.
   Torque spec

   Starter Mounting Bolts50 Nm (37 lb-ft)
5. 5

   Remove lower starter mounting bolt
   Remove the lower starter mounting bolt while supporting the starter weight. Once this bolt is removed, the starter will be free. Carefully maneuver the starter out from its mounting location, being mindful of tight clearances around frame and steering components.
   Torque spec

   Starter Mounting Bolts50 Nm (37 lb-ft)
6. 6

   Inspect mounting surface and flywheel
   With starter removed, inspect the mounting surface on the bellhousing for damage or debris. Check flywheel ring gear teeth for wear, chips, or missing teeth. Clean mounting surface with wire brush if needed. If flywheel teeth are damaged, further transmission work may be required.
   ℹ️Damaged flywheel teeth can cause grinding noises and starting failures even with new starter
7. 7

   Compare old and new starters
   Verify new starter matches old unit in mounting bolt pattern, nose cone length, and electrical terminal configuration. Check that the pinion gear engagement depth is the same. Transfer any shims if present on original starter.
   ⚠Incorrect starter nose cone length will cause pinion gear to not mesh properly with flywheel
8. 8

   Install new starter motor
   Maneuver new starter into position, aligning mounting holes with bellhousing. Install both mounting bolts hand-tight first to ensure proper alignment. The longer bolt typically goes in the upper position.
   Torque spec

   Starter Mounting Bolts50 Nm (37 lb-ft)
9. 9

   Torque starter mounting bolts
   Using torque wrench, tighten both starter mounting bolts to specification in a cross pattern (alternate between upper and lower). Ensure starter is seated flush against bellhousing with no gaps.
   Torque spec

   Starter Mounting Bolts50 Nm (37 lb-ft)
10. 10

    Reconnect electrical connections
    Attach the B+ cable to the solenoid stud and install the retaining nut. Torque to specification. Connect the smaller trigger wire connector, ensuring it clicks fully into place. Verify connections are tight and properly routed away from heat sources.
    Torque spec

    Starter Solenoid Nut12 Nm (9 lb-ft)
11. 11

    Reinstall heat shield if equipped
    Position heat shield over starter motor and install mounting bolts. Torque to specification. Ensure shield is properly positioned and not contacting moving components or wiring.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
12. 12

    Reconnect battery and lower vehicle
    Reconnect negative battery cable to battery terminal and tighten securely. If vehicle was raised, remove jack stands and lower vehicle to ground. Ensure all tools and parts are removed from under vehicle.

Reassembly

1. Verify all electrical connections are tight and properly routed
2. Confirm heat shield is installed if originally equipped
3. Double-check that no tools or parts remain in engine compartment
4. Ensure battery is reconnected with clean, tight connections

Verification

• Turn ignition key to START position and verify starter engages smoothly without grinding noises
• Engine should crank at normal speed without hesitation or unusual sounds
• Release key and verify starter disengages immediately with no continued spinning
• Check for any fluid leaks around starter mounting area
• Test start engine 2-3 times cold to confirm proper operation
• Verify no warning lights on instrument cluster related to charging system

Related trouble codes on this vehicle

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