Clicking when starting cold

[Halfdane]

2016 ram 3500 6.7 Cummins turbo diesel flatbed white DRW.

I’ve been having a problem during colder days of the year. When I turn the key for startup, there’s an audible click from somewhere forward of the driver dash area. After the first click, there’s a battery voltage drops about 2V, from 14-13VDC to 12-11VDC. After about 2-3 seconds, there’s an audible click again like the first time, and the voltage goes back to 14-13 and stays there. This process repeats for about 5 or 6 cycles, and then I get a message envelope light, and the message is that the truck is in battery saver mode.

I asked a couple diesel mechanics and ram owners in person what they thought of this. They stated something about a bad heater box or some such thing. Not the heater core, a heater box. This was a few years ago and since it’s never caused a problem to the truck overall (that I know of), I never resolved the problem. Now I am thinking it’s causing another error code, a P0607 I think, which is a code about the electrical system having an issue or the ECM being bad. The truck never runs poorly or differently, and the MIL for the P0607 goes away over time, so I’m guessing the code has to do with the issue with the clicking and voltage drop.

Does anyone know about this heater box? Or is the issue something else? Again, this only happens when it’s below 60 degrees outside and when the truck is cold. The diesel mechanic showed me this heater box and it was about 3 inches square and 2 inches deep. Any information is helpful and thanks in advance.

 

[Mojo88]

For weird elec issues - the first things I always look at are battery cables and grounds. I see some guys posting on here about actually adding EXTRA grounds.

 

[smittyd174]

My 2016 3500 would do this on cold days occasionally. What it is the truck can disable certain unnecessary high draw things such as heated seats steering wheeland other accessories to allow for maximum power to the grid heater which is the little box you spoke of . This gives max power to that and the starter . The clicking may be caused by the relays for the heater which draws a lot of battery power causing the voltage drops . You can tell the heater is kicking in and out at night because the headlights dim .
Most diesels use glow plugs to warm up the cylinders prior to start Ram chose a grid heater . It will cycle on and off till the engine starts generating heat . The battery saver mode message will go away on a restart after warmed up . One last thing keep an eye on the grid heater bolts they can loosen up . Google it . Hope this helps .

 

[smittyd174]

Follow up to previous post about grid heat . From what you described it sounds normal except for one thing you said 60 degrees . At 60 you should be able to just start it no wait to start needed . That's t shirt weather .
I live on the east coast of Canada and my theory on starting the truck was us remote start . 5 -10 seconds it's OK, 10 -20 seconds need gloves and a hat over 30 seconds too cold going back to bed .
Never an issue til it got below freezing , did you know that truck has a high idle feature as well . Start truck , turn on cruise control and press the increase speed button , it will go up to about 1500 rims if you keep pressing it .

 

[Halfdane]

@smittyd174

Thanks for your help. Based on your post this is what I discovered.

It is definitely something to do with the grid heater. I researched information on the internet and found a way to troubleshoot the intake system. I guess I got lucky that the grid heater relay didn’t stay in the closed position, melt the bolt and bracket, and put me out a new engine! I do think the heater solenoid is stuck open and won’t close to turn on the grid heater.

Following a video I watched, I removed the positive from the solenoid near the battery and secured it. I started the truck after three dings on startup, and I still hear a set of clicking sounds. I’m guessing this is coming from the solenoid near the battery. It still cycles about six times, but the voltage drop has stopped, the clicking has a softer sound, and there is no message about “battery saver mode”.

Thankfully this journey taught me about the air intake system that the grid heater is attached to. What an engineering nightmare for the owner! What would be the most cost effective way to resolve the issue? I’m at 266k miles on this truck and I want it to last. Do I drop the money on the banks intake kit or are there other options in your opinion? Thanks.

Also, in the south, if it’s 60 or below it’s pants and jacket weather. =D

 

[smittyd174]

At 60 the grid heater shouldn't be coming on in my opinion. Anything above 50 it should just start . Mine would start at -10 f would take about 20 - 25 seconds on remote start . Never had a grid heater issue but that bolt is fatal if it drops .
The Banks intake still uses a heater just in a better spot . Unless your very mechanical inclined I wouldn't tackle it although Banks has got there stuff together . You have to move a couple fuel lines . Good luck.

 

[smittyd174]

Original batteries? Maybe get weak .

 

[Halfdane]

@smittyd174

I don’t have any information as to why the grid heater is engaging at 60 degrees outside temperature or less. Maybe the temperature sensor is bad.

As for doing a grid heater delete, I am comfortable in my technical skill to do this. After the delete, I have a diesel mechanic that has done a tuning kit for my truck and I will take it to him to do the ECM/FICM adjustments if necessary to prevent any MIL lights even though the adjustments are upgrades and not malfunctions.

The batteries are not original, they are Optima batteries and they are about 4 years old. Getting close to the end of their lifespan.

Thanks for your help, have a wonderful holiday season.

 

[06 Dodge]

FYI the Cummins grid heater comes on any time the manifold air temp reads 66 degrees or below, it been that way for many, many years and yes you can by pass the grid heater and start the engine without waiting for the grid heater to run its heating cycle...