IK0800407 ­ Starter Diagnostics and Warranty Claim Procedure (Excl : ISB engine /Allis... Page 1 of 5

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Title : Starter Diagnostics and Warranty Claim Procedure (Excl : ISB engine /Allison trans)
Applies To : All engine, all chassis, excl : ISB engine /Allison trans

CHANGE LOG
04/04/2016 - Changed applies to all engine, all chassis excl. ISB/Allison Transmission equipped vehicles
03/14/2016 - Added link to Navistar Starter and Alternator Warranty Quick Reference Guide.
11/18/2015 - Updated Author for feedback purposes.
07/20/2015 - Moved diagnostic worksheet link to before step base diagnostic steps, simplified diagnostic steps
04/14/2015 - Updated to new iKnow article criteria. Revised Diagnostic steps

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DESCRIPTION
The following information details the procedure for proper starter diagnostics and requirements for warranty. Use of this document will
increase confidence that the right repair is made with minimal downtime and requires the use of the MidTronics EXP tester and the
Starter Diagnostic Worksheet.
Note : This doesn't cover CE Bus/DuraStar/WorkStar equipped with ISB engines and Allison Transmissions. See IK0800503 .

SYMPTOMS
Diagnostic Trouble Codes:
DTC/Light

Description

N/A

Customer Observations or Symptoms:
• Click, No-Crank (solenoid clicks, starter does not crank, engine is in a no crank; no start state)
• No-Click; No-Crank (solenoid does not click, stater does not crank, engine is in a no crank no start state)
• Slow Crank (control circuit working, solenoid working, starter cranks the engine, engine is in a slow or no start state from cranking to
slow)

SPECIAL TOOLS / SOFTWARE
Tool Description

Tool Number

Comments

Midtronics EXP

EXP 1000 HD

Dealer essetial tool per SFN­07­77

DIAGNOSTIC STEPS

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IK0800407 ­ Starter Diagnostics and Warranty Claim Procedure (Excl : ISB engine /Allis... Page 2 of 5

Following the step based procedure below will determine if there is an issue with a starter motor and help prevent warranty denials for No
Trouble Found (NTF).
When testing for a Starter related failure, the technician will complete the proper diagnostic worksheet. Critical diagnostic testing values are to be printed and
submitted with the claim.

NOTE: Before performing any voltage drop test; inspect each cable end nut torque, insulation, routing, clipping, discoloration,

and terminal arching

Step Action

Diagnostic Trouble Code Check:

1

Decision

Yes. Go to appropriate diagnostic manual
to diagnose crank no start symptom

Review current health report for fault codes that may cause an extended crank
condition (Crankshaft Position Sensor, Camshaft Sensor, Fuel System, Electrical
codes)
No. Step 2
Are there pending/active/previously active DTC's causing a crank no start?

Step Action

Manual Engine Barring Test:

Decision

Yes. Step 3

Have an assistant bar the engine over from the alternator pulley
2

TIP: If an audible noise is heard from the starter area when the engine is
rotated by hand, there is most likely flexplate ring gear damage.
No. Diagnose engine lock up condition.
Does the engine rotate freely?

Step Action

Cranking RPM Test:

3 Monitor Engine RPM while cranking the engine

Decision

Yes. Go to appropriate crank no start
diagnostic. Do NOT replace starter motor
No. Step 4

Does the engine crank?
Step Action

Perform battery test:

4

Decision

Yes. Replace ONLY failed battery and
then recheck for symptom

Follow IK0800482- Battery Testing, Diagnostics & Maintenance
No. Step 5
Is a warranty approval code (WAC) or failed battery result from any battery
generated?

Step Action

5

Decision

Starter Cable Voltage Drop Test:

Yes. Make required repair

Follow Midtronics starter cable voltage drop test

No. Step 6

Is combined + & ­ voltage drop greater than 0.5v?
Step Action

6

Alternator Cable Voltage Drop Test:

Decision

Yes. Make required repair
No. Step 7

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Follow Midtronics alternator cable voltage drop test

Is combined + & ­ voltage drop greater than 0.5v?

Figure 1: Starter IMS S terminal DVOM Hookup Location

Step Action

Starter Control Circuit Check:

Decision

Yes. Perform starter control diagnostics for
possible causes:
Wiring

Connect DVOM test leads on IMS (Mag switch) "S terminal" and ground to solenoid F3A Fuse
Start Relay (Neutral Relay)
case as indicated in Figure 1
Crank Inhibit Relay
7

Have an assistant hold keyswitch in start position for 5 seconds.
Compare DVOM to B+ at batteries

Clutch Switch (Manual Trans)
TCM (Auto Trans)
ECM
Key Switch

No. Step 8
Does the DVOM not read battery voltage +/-0.5 volts?

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Figure 2 Flexplate/Flywheel Ring Gear

Step

Action

Decision

Ring Gear Inspection:

Yes. Step 9

Remove starter
Mark the flexplate ring gear with a paint pen
8

Have an assistant bar the engine over while you inspect each tooth for damage:
burrs, milling, chips, etc. (Figure 2)

No. Inspect each tooth

TIP: This can be done as a one man operation using a borescope or by
looking through the starter mount hole

Did all teeth get inspected?

Step

Action

Decision

Repair Determination:

Yes. Replace ring gear & starter
No. Replace starter

9
Does the ring gear require replacement when comparing to Figure 2?

WARRANTY INFORMATION
Warranty Claim Coding:
Group:

08540- Cranking System

Noun:

202- Motor, Starter

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IK0800407 ­ Starter Diagnostics and Warranty Claim Procedure (Excl : ISB engine /Allis... Page 5 of 5

Standard Repair Times:
Description

Chassis

Engine

SRT

Hours

Starter Diagnostics

All Chassis

All Engines Click Here 0.9

Special Requirements:
As of November 1, 2012:
When testing for a Starter related failure, the technician will complete the proper diagnostic worksheet. Critical diagnostic testing values are to be printed and
submitted with the claim.
A copy of the completed diagnostic worksheet should be retained with the warranty claim repair order.
All Starters replaced under Warranty (Warranty Codes 01,03,39,55 and 98) will be requested back to be reviewed and tested. Any which are found non-defective
or unnecessarily replaced will be charged back to the dealer.
*Also now available Starter and Alternator Warranty Quick Reference User Guide*
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