thevervaeckes

Wed. the starter relay went out at a local market, replaced and was fine from Thur. morning to Sun. evening. Went to the same damn market... starter relay burned out again. Replaced with brand new one and burned our after driving across the street? What could this be all about? Jeep has power (radio and lights work) but will not turn over with the key. Can manually turn it over with a screwdriver in the engine, but don't want to have to keep doing that with the wife and kids in the car...

Any help?
Brent

5-90

What year?

One summer, I had a similar problem with RENIX (1988, to be exact.) Since those starter motor relays were about forty bucks a pop at the dealer, the local parts house didn't have them, and Beck decided he wanted to go through them like popcorn, I got tired after buying the third one in a month.

I replaced it with a Bosch/DIN relay, and that was the last time. For some odd reason, I haven't blown out a starter motor relay since - and it's been something like six or seven years now (and if I do, I have plenty of spares!)

The advantage to this is that a DIN relay can be had pretty much at any local for ten bucks or so, and you should have a couple of spares in the box with your fuses and lamps anyhow.

I never did figure out why Beck decided to start munching starter motor relays, but I was glad when I did a fix that didn't need to replace them anymore (and replaced with something that I buy in bulk anyhow!)

thevervaeckes

its a 96 with the 4.0 auto, 4wd. I went out to it later after it didnt want to start with out arching the starter and wiggled the crap out of the relay and it fired right up. So i guess tomorrow night I am going to pull the relay box and trace the wires to see if they are corroded or loose somewhere. I hope thats the problem

thevervaeckes

so tonight i traced all the wires that go to the start and the battery,no loose wires in the main fuse block,no frayed wires that are shorting out anywhere. So i put some di electric grease on the relay prongs, and some grease on the the solenoid wire. Started it up and shut it off over 50 times no problems, drove about 10 miles,to the store shut it off and it fired right back up. so either the relay wasnt making good contact or it is just intermitently working now. Any ideas anyone?

5-90

So you're a later model - the relay is about a 1" cube? That's a DIN relay - just replace the thing. You should keep a couple spares on hand anyhow (the DIN relay is used all over in the XJ - all years. Later models also use the mini-DIN relay - it's about 1/2"x1"x1", and you should keep a couple of those handy as well.)

JeepKnut

Make sure you have a good ground where the bolts go through or get an insulated one.
You may be going through alot of them because the current is to much for the relay.

thevervaeckes

So now the relay is getting hot,and when it's hot it won't start.so I guess it is getting to much voltage now, what could this be? Could it have a bad ECM? Any help would great,thanks

Fred1diver

I can't seem to get mine started, where can I find the starter relay on a 96 xj
Thanks in adv.

FRED

Fred1diver

O.K. so I found the relay, I'll open my eyes when looking next time, promise
the relay is good so is the solenoid, at least it clicked.
so
I took the starter out, now are those things rebuildable or should I save my time and buy another
thanks in adv.
FRED

thevervaeckes

I would go to your local store and buy a new one with a lifetime warranty. Never have to worry about buying another one. I replaced the starter and it took care of all my problems. So this maybe your problem too.

Abidin

You can check the starter motor bushing (inside the motor), or the motor's carbon brush...it works several times to my client

Fred1diver

thanks guys.
I took the starter apart last night and the commutator has one strip half missing and another who has been shorted badly, the brushes are also badly worn. so I guess it's time to find some money and get a new one.
talk to you soon
FRED

Fred1diver

so what do you think caused this

5-90

Ow!

See how it's melted where it's gone, instead of just broken out? That would be an overcurrent condition, and may have been from a "void" in the material. It just took time to make itself apparent.

A void in the material would reduce the ampacity of the circuit - similar to using a wire too small for the current you're sending through a circuit. Since the starter motor draws something like 160-165A when cranking, this can be very important (low duty cycle, which is why it lasted as long as it did. Inefficient cooling of the starter motor comm rings, which is a lot of why it's a problem.)

A one-in-one thousand problem, and the dice just came up snake eyes for you, is my take on it. I've seen it maybe a dozen times in thirty years of working on pretty much everything (cars, trucks, heavy trucks, forklifts, cranes, ...)

Fred1diver

well I changed the starter today and it works like a ....JEEP
finally, last week the rad. and the alternator. this week battery, wich I don't really need and wally wolrd won't take it back , and the starter.
O.K. I admit I didn't pay much for the jeep but for the repairs....
talk to you soon
FRED