ms52390

Hello all, been using the forum for some time now and I felt it was about time I registered.

I have a 1996 4.0L 5spd 4door XJ! Shes a beast but i have encountered a strange issue. It will not start, here is what i have done so far:

Disconnected the starter, alternator and removed the positive connections going to the main fuse panel. I pulled the battery out and did some beep tests with a multimeter. Here is what i found:

Battery terminals - No beep
Fender ground to main fuse panel bolt - No beep
Fender ground to several other grounds - got beeps

Judging by those tests it seemed like there was no short, so I plugged the alternator and starter back up. When I turn the key on i can hear some clicks sounds coming in the area of the main fuse panel, and some dash lights/ radio come on but with the key in the start position the starter doesn't kick over.

I have however been able to start the jeep by jumping the starter with a screwdriver. Odd thing, with the key ON, my starter gets a constant 11.9 volts.

Anyone have any ideas?!

Radi

Try staring in Neutral, if that doesn't work try jockeying the shifter around while holding the key in start. The Neutral safety switch (NSS) is a common cause of this.

ms52390

I have tried starting in neutral and played with the clutch a little. Just to add in: If I remember correctly the rear tail lights weren't working but the headlights were. This Is why I went hunting for a short due to all the odd behavior.

Radi

Whoops, I completely missed the fact you have a manual trans. Check the small wire at your starter solenoid for +12V when you turn the key to 'start'. A long chunk of wire and alligator clip makes it easier.
If there's nothing there, work your way back through the start relay in the PDC- relay coil should have power with key in 'start'. Coil ground is supplied by the neutral safety switch in an auto, not sure what a manual has.
If nothing there, check ignition switch.

salad

Clutch interlock switch rides on the plunger above the pedal. It will prevent the various starter relays from being energized

karl4x4

Seems like you have a case of the worn out brushes in your starter.

If the green (little one) on the starter is getting power when you turn the key and the battery voltage is not really going down at the same time, there are your possible options by likelyness

-worn out brushes on the starter (power for the solenoid has to go true the brushes to energize) (simple fix. replace the brush assy)
-Bad ground connection (put multimeter between engine block and battery negative terminal. any voltage read is voltage lost. find the bad connection)
-bad positive connection. (put multimeter between begining and end of circuit on same line. any voltage is voltage lost. find the bad connection)
-if all of the above are good, the starter solenoid may need a good cleaning or replacement. (there is a big contact inside that gets dirty/oily)

PS: "beep" test is called a continuity test. When it beeps there is a short.

mr white

If you can jump the solenoid and it starts, your solenoid is probably dead. You can try smacking it with a hammer to see if it frees up and then try starting it. Could also be the clutch safety switch deal or ignition switch.

ms52390

You guys rock, I am loving all the info and will be playing with stuff tonight.

My starter gets 11.9 volts with the key on and in the start position, is this normal?

karl4x4

Compare from start to off with key. Should be a couple volts drop caused by the electrical load of the starter. Seems to me their is no load.
What about green little wire on starter?

ms52390

Little green wire? I have a black and red wire going to the solenoid then another wire (i think its red?) going from the solenoid to the starter. Is there another one that I'm just not seeing?

karl4x4

I could be wrong about the colour. I've always seen it green.
Its the only wire going to the starter (Its actually connected on the solenoid that is on the starter) that is about a size 14gauge. Much smaller than the battery cables

Starter(solenoid) has one big positive wire dirrectly from the battery terminal and one small one going to starter relay

cruiser54

You can't even SPELL color for crying out loud!! LOL.

mr white

For'ners.

cruiser54

Hopefully Karl is a fun loving guy with a sense of humor from Canuckistan.

salad

Lol. You really like that one don't you