Starter Repair

I just repaired the starter on my '97 Voyager -- by replacing the 2
contacts.

However, looking on eBay, I see many auctions for a repair kit that also
include the plunger. Is replacement of the plunger also necessary?

Also, in the process of repairing the starter, the drain hose/plug broke
off (the rubber was quite brittle from age). Is is possible to replace
this? If so, do I have to lever the remaining plastic out (the piece with
a rectanglular slot, visible in the round hole in the aluminimum body of
the starter)? And where would I buy a replacement?

 

I had my stater fixed at a local rebuilder a couple of years back.
They replaced the 2 contacts. But they also put the plunger on a
lathe, and machined it flat and shiny again. The action of the plunger
hitting the contacts every time you start causes the contacts to wear,
and the surface of the plunger to become pitted. If you do not replace
plunger, or refinish the contact surface, then your new contacts will
wear out quicker than the old ones.

So is it necessary? You can probably get away with not replacing it.
If you are going to keep the van, then replace it. If not, then don't.

 

I've fixed at least 5 (that I can recall) separate Nipondenso (Chrysler OEM)
starters by replacing just the copper contacts. In all cases I thoroughly
cleaned the plunger with a good stiff wire brush and then used electrical
contact cleaner ..

I have had no repeat starter problems on any of those vehicles. That said,
the absolute correct way to do this job is probably to replace the plunger
contact as well since it too gets deformed/damaged by the high current, but
since it moves around and does not always contact the same spot each time
(unlike the fixed point contacts), it is in much better shape.

Bob

 

Need to know the proceedure for removing stater from 1999 Chyrsler 300M.
Thanks for any help.