Starter Replacement 6.5L Diesel

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine cover. Refer to Engine Cover Replacement .



3. Remove the starter motor nut retaining the starter to the starter motor bracket.
4. Remove the starter motor bolts from the engine.



5. Disconnect the electrical connectors from the starter solenoid.



6. Remove the bolt retaining the starter motor bracket to the engine.
7. Remove the starter motor from the engine.

1. Install the starter motor to the engine.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




2. Install the starter motor bracket and bolt to the engine.

Tighten
Tighten the bolt to 17 N·m (13 lb ft).




3. Connect the electrical connectors to the starter solenoid.

Tighten

•	Tighten the battery cable to the solenoid to 10 N·m (89 lb in).

•	Tighten the ignition switch wires to the solenoid to 6 N·m (53 lb in).




4. Install the starter motor bolts to the engine.

Tighten
Tighten the bolts to 45 N·m (33 lb ft).

5. Install the nut retaining the starter to the starter motor bracket.

Tighten
Tighten the nut to 10 N·m (89 lb in).

6. Install the engine cover. Refer to Engine Cover Replacement .
7. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Starter Replacement 8.1L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable (1). Refer to Battery Negative Cable Disconnection and Connection .
2. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



3. Remove the starter motor bolts.
4. Lower the starter motor.



5. Disconnect the knock sensor (1).
6. Remove the engine harness nut (2).
7. Remove the engine harness (3) from the starter.



8. Remove the positive cable nut.
9. Remove the positive cable from the starter.
10. Place the starter motor on a work bench.



11. If necessary, remove the starter heat shield bolts, nut and shield.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. If necessary, install the starter heat shield, nut and bolts.

Tighten

•	Tighten the starter heat shield bolts to 3 N·m (35 lb in).

•	Tighten the starter shield nut to 5 N·m (44 lb in).

2. Place the starter motor into position.



3. Install the positive cable to the starter.
4. Install the positive cable nut.

Tighten
Tighten the positive cable nut to 10 N·m (89 lb in).




5. Install the engine harness (3) to the starter.
6. Install the engine harness nut (2).

Tighten
Tighten the engine harness nut to 2 N·m (18 lb in).




7. Raise the starter motor into place.
8. Install the starter motor bolts.

Tighten
Tighten the starter motor bolts to 50 N·m (37 lb ft).

9. Lower the vehicle.



10. Connect the negative battery cable (1). Refer to Battery Negative Cable Disconnection and Connection .

Starter Replacement 4.3L, 5.0L, and 5.7L

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .



2. Remove the starter motor brackets and shields, if equipped.



3. Disconnect the wires from the starter solenoid.



4. Remove the bolts and the shims, if present, from the starter motor.
5. Remove the starter motor from the engine.

1. Install the starter motor to the engine.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolts and the shims, if present, to the starter motor.

Tighten
Tighten the bolts to 45 N·m (33 lb ft).




3. Connect the wires to the starter solenoid.

Tighten

•	Tighten the battery cable to the solenoid to 10 N·m (89 lb in).

•	Tighten the ignition switch wires to the solenoid to 2 N·m (18 lb in).




4. Install the starter motor brackets and shields.
5. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .