I went to start my CRD last Friday and nothing happened. No Crank/No Start. On checking the Power Distribution Center the 40 Amp PAL link for the starter circuit was fried. I switched the starter relay and relpaced the 40 Amp PAL and tried it again. Same results -- No Crank and another blown Link. The wiring from the PDC to the starter checked out OK. But there was a dead short across the solenoid power wire post and ground. Problem fixed with a new Starter @ $ 193.00 plus tax.

The CRD has 62,000 miles on it. Has anyone else experienced this or am I just lucky? I hope this info can help someone along the way. Kemosabe

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2005 KJ CRD
2008 KK
1940 Cletrac BDH with Mitsubishi Diesel

Sounds like you are a lucky guy. I've not heard of any starters failing yet, and that's a strange failure mode too.

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'05 Liberty CRD B100, SEGR - SOLD

'01 Beetle TDi B100, EGR delete
'83 Mercedes 240D B100, no EGR

--- SEGR Builder ---

Dead short across the solenoid, wow, never heard of that happening on any vehicle.

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2005 CRD "Ol' Blue"
Red Ryder carbine-action, two hundred shot range model air rifle with a compass in the stock and this thing which tells time.
My build page- RL Komodo Rear and TJM Front Bumper, armored, lifted, JBA Steel D30, 4.10s and ARB air lockers.

I saw it on a chevy chevett. A wire broke off inside the solenoid where it fastens to a screw. There was no fuse, things just got hot

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Atlantic Blue 06 CRD Limited (his)
Joined by a 2000 XJ Classic (hers)

I thought it was strange when there was no sound whatever when I turned the key to the start position and blew the fuse. If it's a dead short in the starter you at least hear the solenoid click. That did not happen on this one. Somehow the solenoid fried itself shut. Oh well just lucky I guess. I hope no one else has the same luck.

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2005 KJ CRD
2008 KK
1940 Cletrac BDH with Mitsubishi Diesel

Likely the contactor washer split and shorted to the housing, requiring only a solenoid kit to fix, but we'll never know now................

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'05 CRD Limited
Pricol EGT, Boost
GDE Hot '11; EDGE Trail switched
SEGR; Provent; Magnaflow;
Suncoast T\C, Transgo Tow'n'Go switch;
Cummins LP module, Fleetguard filter, Filterminder
2.5" Daystar f, OME r; Ranchos; K80767's, Al's lifted uppers
Rubicons, 2.55 Goodyears
Four in a row really makes it go

I had some time this weekend to look at the no crank starter. Took the solenoid off. The arm for the starer gear and the pin that move it are nylon. Every thing was free and worked well. The motor itself could be turned but seemed a little stiff. I used the tried and true solenoid repair technique of tapping it several times on the work bench. Reassembled the solenoid and tried it again. It worked. I'll look for a new soleniod and brushes, but it's like the fuel heater; you cannot buy just the piece you need. You have to buy the whole assembly. Kemosabe

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2005 KJ CRD
2008 KK
1940 Cletrac BDH with Mitsubishi Diesel