2005 TJ has intermittent starting issues

[cormorant tail kite]

86,000miles 2005. Past few months jeep has been doing intermittent starts, every few weeks I would turn key to start, would get the first sound of start sequence and then get a loud thunk!,(da, thunk) then nothing. Tried key again, silence, lights come on that's it. After a few tries it started. Took her a few times to auto places to do their battery/alternator/starter test and test says good for each. Checked all connections, hardly dirty, shined up connections, tested (7monthold) battery 12.06 rest. Starter, all numbers seem ok? Starter rest 12.06-.26, fired up 11.99-10.64. there was a bad connection wire to solenoid(rest 12.36, started 11.40, put new end on but didn't fix starting issues.

Now, it's doing a long labored start, when you turn key over the da da da dumm to start sounds like it's on relaxers, daaaadaaaaadaaadummmmmmm. Ha sorry. And she's worked her way to the present of really drawn out, hardly sounds like it's wanting to catch and when it did catch could hear something like it's like a muffled, buzzed rattle, not loud or long duration, just off. Maybe hearing the starter spin? Any thoughts at all would be greatly appreciated! I'm feeling it's getting near thw not starting at all time

Could starter/solenoid be bad even when numbers seem ok and store test said ok?

 

[NashvilleTJ]

Given the various noises you are trying to describe, it sounds like it could perhaps be the starter. Which “store” tested it?

But more likely you have a bad or weak electrical connection somewhere. Are you sure the cables are all OK? Specifically the cable on which you replaced the end? On an 18 year old rig it would not be a bad idea to replace the cables if they are original as a matter of course.

 

[cormorant tail kite]

Autozone and Advance, the tests they do on the battery to test alternator, battery starter, even asked advance to do inside vehicle plug test, even though there is no check engine lights, just to see and nothing was showing.
The end that needed a new end was the wire to solenoid from the cluster of wires that go to everything in center of jeep. Not the battery set of wires.

 

[Jerry Bransford]

Turn your interior lights on then try starting it. Do the interior lights dim and shut off or do they stay at full brightness while the engine is not starting with the key in the Start position?

 

[cormorant tail kite]

Just tried it, full brightness with just key on position and as doing full turn over, almost 100 percent they dimmed may a tenth of a percent, but hardly at all.
This start up, was a good start just slightly slow

 

[Jerry Bransford]

Just tried it, full brightness with just key on position and as doing full turn over, almost 100 percent they dimmed may a tenth of a percent, but hardly at all.
This start up, was a good start just slightly slow

Try that again the next time it won't start. Try this too, that issue can be caused by dirty, corroded, or loose battery connections. Go buy a $5 battery brush at your local auto parts store and use it to get the battery posts and inside of the battery connections bright and shiny clean, then make sure both battery connections are good and tight when you're done. No, don't just look at the battery connections and think they look ok and not do this, they can look fine/great and still be bad.

 

[cormorant tail kite]

Yes, I have cleaned every connection except on the block, sprayed cleaner on just can't get it loose. I took battery cables off cleaned both battery and connections, the ground and alternator connection, and both starter and solenoid with wire connections all are shiny now, nice and clean. And it did not fix start issue
I realize wires can be issues for many things, but with that klunk sound she made sometimes when I turn key over is why I thought starter. Somehow not engaging properly in it's spin. Sorry don't know terminology, just see it in my head.
Wonder if an even ok multimeter reading, if can still be bad motor in starter?

 

[cormorant tail kite]

Update on what's still going on. I replaced starter due to final sluggish start then a no start with a click. Replaced with a new, not refurbished starter. When I put starter in I looked at the flywheel teeth all looked good. When I started jp she started right up but the stater was louder, afraid something was wrong I had my man try to start it while I lay on ground to listen to starter and it wouldn't start. Every time we would switch places to start, she'd start for me and not him, at least a dozen times. Consistantly. When he was trying to start it I looked at interior lights and they did not dim at all. Days later had a buddy try to start, same thing, would not start for him. And again went to visit my man and no start for him. Amazing! Past 3 weeks she has started for me every time, now she's doing same thing as pre-new starter, turn key get one clunk, no start. This is still intermittent, she still starts after a few tries. I tried switching relays and no change.
Any thoughts would be great!!
Thank you

 

[Link]

I’d be looking at your starter switch on the column.

https://www.amazon.com/gp/aw/d/B00FRFIGSQ

You can buy one but don’t take the old one off yet. Unplug the plug and plug it in to the new one. Use a flat head screw driver of the appropriate size to turn it on the new one to start it. See if that changes anything. If you have the SKIM key I believe you’ll need to actually install the new switch to test it.

 

[cormorant tail kite]

I’d be looking at your starter switch on the column.

https://www.amazon.com/gp/aw/d/B00FRFIGSQ

You can buy one but don’t take the old one off yet. Unplug the plug and plug it in to the new one. Use a flat head screw driver of the appropriate size to turn it on the new one to start it. See if that changes anything. If you have the SKIM key I believe you’ll need to actually install the new switch to test it

Thank you for the link and the screwdriver tip. I was thinking about the ignition switch or actuator pin. Debating on ordering both just in case. Do you know if that ignition switch part is manual or automatic specific? When I was reading the part reviews someone mentioned that didn't work for them because of it, not sure if it's accurate.

 

[Link]

Thank you for the link and the screwdriver tip. I was thinking about the ignition switch or actuator pin. Debating on ordering both just in case. Do you know if that ignition switch part is manual or automatic specific? When I was reading the part reviews someone mentioned that didn't work for them because of it, not sure if it's accurate.

Mine is a manual and that’s the one I installed. I’m sure they are the same. Not a bad idea to replace the actuator as well.

 

[cormorant tail kite]

Updates. I installed the ignition switch and actuator pin, both Dorman. When I took out the actuator, the spring wasn't seating in the round hole in the bottom and when you pushed at end where key is pushed the plastic sometimes sat on that raised plastic in the center that it's not supposed to go over. Also, the switch had a slightly darker copper section, not sure if that was anything, I replaced it anyway. I made sure that spring was seated properly. Haven't had any no start issues for last 6 weeks. Yayy!
Now.. wipers did not work, no spray, nothing. Got home, shut her off, and played with key in ignition, they worked when jeep was off, started her up they worked. As I was starting, there felt like there was play with the key. So while it was running I just touched it slightly and she stalled, ran it a few times and each time if I would just turn key a bit she wanted to cut out. You have to pay attention to the seating of the key to make sure wipers work when in start. My question, could this be a faulty actuator pin? Ignition switch? Or something new?
Thank you for any ideas