Another no start puzzle!

[Frank12345]

Brand new battery, got it today. Also it reads 12.5v on multimeter

When I turn the key, the fuse box behind the glove box clicks, the asd relay clicks, but the starter relay does not click.

I have a 20amp fuse in the #20 slot of the fuse box which I understand bypasses the clutch safety switch.

When I bridge the posts on the starter with a screwdriver she starts no problem.

I'm considering a push button that closes a switch between the posts on the starter as my new ignition switch, but I'd like to fix it properly.

Any ideas?

 

[macleanflood]

Actuator pin?

-Mac

 

[Frank12345]

I replaced it recently and it ran fine for a few months after. But it definitely could be a problem again. Would power be getting to the asd relay if that was the problem though?

 

[macleanflood]

Maybe the ignition switch then?

-Mac

 

[JKP]

When the pin breaks, everything works but the starter.

Check the starter relay in the PDC also.

 

[Frank12345]

I swapped the starter relay in the PDC with a few others and a spare and got the same result.
I believe I replaced the ignition switch when I replaced the actuator pin. Is it common for either of those to be bad out of the box? I've probably started it only 100 times since replacing those. Maybe I weakened them during install.

Could it be the PDC itself?

 

[Frank12345]

I did pull the bottom cover off the PDC and found a bare wire corroded almost all the way through and repaired it, but it was running from the accessory fuse. And it looked like the insulation was worn through by the bracket holding the PDC and not from something that would affect the whole PDC

 

[macleanflood]

Shoddy previous owner wiring. Leading cause of Jeep fires and frustration.

Take a look at @Woodrow 's build thread. He had to drop his gas tank and unhack his rear tail light harness.

If you found one you'll probably find more.

Yes it's very common for new parts to immediately fail.

My new ignition pin already feels "crunchy" and almost stuck in the crank position.

I have a rusted out 2000 Sahara...might steal the pin from it as a trail spare.

-Mac

 

[Frank12345]

Ok, so i went in the steering column, disassembled all that, didn't find anything that looked bad, so I started putting it all back together. I turned the actuator pin by turning the key cylinder with my hand and it started. I put it all back in place and held it in place with my hand, turned the key and it started. I put the bottom cover back on (the one that has the plastic button attached to it for removing the key) and it wouldn't start. I loosened the screws that hold it in place and it started. I was so confused I did it back and forth a few more times and screws tight it wouldn't start, screws loose enough that that bottom cover wiggles around, and it starts. It almost feels like the key can't turn quite far enough when the screws are tight and it turns just a hair further when they're loose.

 

[Frank12345]

that's the cover I mean. Tightscrews doesn't start, loose screws starts

 

[Frank12345]

Actuator pin is broken! I just didn't see it the first time because its only a small crack but I'm going to replace it and see if that does it