Strange Starting Issue, One Click Then Dead

[WranglerLJinAZ]

Hey all,

Been chasing this starting issue for the last six months or so on my '05 TJ. Any help appreciated.

Most of the time, I'll put the key in the ignition and the dash will light up normally, but the second that I try to turn it over I can hear a single click (from what I think is the starter solenoid) and it will completely die. No more power whatsoever — dash lights do not even turn of after returning the key to the accessory position, and the car will need to be jumped to get any power back and start.

I say most of the time because, sometimes, the car will start normally without any issues. Even then, there are times where I can drive it for a few hours, turn it off, and then it will go completely dead when I try to turn it back on again (in the manner described above).

Brand new battery and alternator, starter replaced within the last two years, checked for bad grounds. I haven't tested for a parasitic drain, but that doesn't really seem to fit with how it can run normally for a few hours and then die the second that it is turned off. The thing that confuses me the most about this is the fact that after the first attempt to turn it over, it is no longer receives any power whatsoever until a jump pack is connected.

Thanks.

 

[KennethS]

I’ve had that happen with corroded or loose battery terminals. One time I was certain the battery terminals were tight, but one twisted when I tested it. Turn of the wrench and all was well afterwards.

 

[WranglerLJinAZ]

Yeah, should have mentioned that I made sure to clean and crank those down when I put the most recent battery in (a few weeks ago). I'll try taking a wire brush to it tomorrow.

 

[macleanflood]

Inspect the cables carefully... corrosion can creep up inside the insulation.

Check the terminals on the starter and your grounds on the engine block and firewall.

-Mac

 

[CharlesHS]

To further expand on what MAC posted above...
Inspect the insulation of the positive and negative cables to see if the cable insulation are showing signs of retracting away from the battery clamps which would indicate the cables are old and exposed to heat.
Check to see if the strands of wire that make up the cables have either a green or white oxidation build up.
While the strands may pass voltage when tested; when under starting load due high amp draw or engine compartment heat the resistance that the oxidation creates will create the problems you are having.
IF you measure the resistance of the battery cables on the 200M setting and you read more than .10 resistance on the cabling; you should consider inspecting the strands for oxidation and it may be time to replace them.
Five years ago I built my own positive and negative battery cables from 2 ga fine strand cables and even now they measure 0.00 on the 200M setting.

 

[WranglerLJinAZ]

Well it caught on fire, total loss.

Joking. Tried starting it up again this afternoon and it was the same issue — all dash lights on, turn to ignition, single click, dead. I traced the wires and did not notice the insulation creeping back, so I decided to hold off on cutting it open and inspecting every inch of wire. There was slightly visible oxidation on the battery connecting brackets and the wire/frame at the frame grounding point. I went ahead and just unbolted the terminal cables and connecting brackets, as well as the cables from the engine and frame grounding points, and cleaned all of the visible metal on the cables, brackets, grounding points, and nuts with coarse steel wool. Reconnected everything and it fired right up, paused for five minutes and tried it again, fired up again. Measured the resistance between the battery cables and it came up as 0.00 — didn't get a reading before doing all of this though, so no idea what the resistance was at that point.

Seems to be working for now, but I'll be carrying a jump back in my back seat for the next few weeks just in case. Thanks for the help; I fucking hate electrical.