Jeep won't turn over

[Ender451]

I have a 2004 TJ X, I6 engine, manual transmission, 142k miles.


Started right up as usual when I left for work. Went home for as couple hours and went to leave again, turned the key and nothing. Instrument lights go on and needles jump, but doesn't turn over. No clicking or any other sound, just the lights. I check the battery, replace starter, to no avail. Switched the starter relay with another identical one in the panel and voila. Fires right up. Fast forward to the next day...

Starts without issue when I leave for work in the morning, leave to get lunch and it won't start again, same as before. Switch some more relays, but that doesn't work this time. Popped the clutch to start it and drive it home.

Here's what else I tried:

- Connected wire to tab on starter, touched to positive battery terminal and it cranked.
- Connected wire to wire from ignition that is normally connected to tab on starter. When I turned the key, multimeter showed voltage.
- Checked 30a starter fuse in box under hood by the relays; it's fine.
- Put 20a fuse in bottom left spot in box behind glove box, which is supposed to override clutch safety to rule that out.
- Plugged in obd, showed zero codes.

Nothing worked so far. Ideas? Thanks in advance!

 

[hear]

You may have implied that you made sure the negative battery cable ws secured, but you didn't say it so I'm going to say it instead. Check the negative battery cable. Based on other stuff you said I don't think it's that, but always a good place to start.

 

[Ender451]

Thanks for the tip. I disconnected when I changed the starter and did reattach. I actually double checked to make sure it was on tight early today when I was messing with it. Thanks tho!

 

[hear]

Popped the clutch to start it and drive it home.

If this worked, then it would seem that the issue is around the starter. Sometimes these issues are around fuel delivery or spark, but if you can get it running this way then there's an issue with power to the starter. Maybe you knew that already, but I didn't pick up on it at first glance. The wiring that turns on the starter touches a lot of stuff...that it seems to be intermittent points to a short or a ground.

 

[Ender451]

That is very helpful, thanks! I had narrowed it down to an electrical issue, but that is the weakest area of my already limited automotive knowledge. I'll start tracing the starter/ignition wires. Update to follow...

 

[Artsifrtsi]

Have you checked to be sure it isn't the ign switch or the switch actuator? If you leave the jeep open a lot, the contacts in the switch will corrode, and not get contact. Try going from run to start a few times, and see if it will hit at all... (kinda like when an old stereo gets crackly on the volume knob, and you twist back and forth to clean the contacts...)

 

[Ender451]

Have you checked to be sure it isn't the ign switch or the switch actuator? If you leave the jeep open a lot, the contacts in the switch will corrode, and not get contact. Try going from run to start a few times, and see if it will hit at all... (kinda like when an old stereo gets crackly on the volume knob, and you twist back and forth to clean the contacts...)

I take the top and doors off in the spring and leave them off until Fall, so this is a strong possibility. I'll check it out. Thanks!

 

[Artsifrtsi]

I take the top and doors off in the spring and leave them off until Fall, so this is a strong possibility. I'll check it out. Thanks!

We do too… have had only safari top on since Easter… I’ve had the issue with corroded switch terminals. It’s easy to open and clean, but take pics as you go to assist with reassembly

 

[Ender451]

We do too… have had only safari top on since Easter… I’ve had the issue with corroded switch terminals. It’s easy to open and clean, but take pics as you go to assist with reassembly

And you win the cigar! Not gonna lie, when I started taking this apart I was afraid you were messing with me because it was kind of a pain. But, once I got it the actuator off, turned out I got a busted pin. Tried to attach a picture, so you can see it if I did the attachment right. Thank you so much, I had not even heard of that problem before and would have spent a lot of time needlessly staring into the engine compartment.

Thanks again for the tip!