Novak Conversions Jeep Wrangler TJ engine mounts

Where do I start with all these issues?

smokehound_tj

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Nov 21, 2024
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Durham, New Hampshire
Few different issues here,

First let's start with electrical....
I had for a while my driver's side turn signals wouldn't work properly if I turned on my headlights. It would make the left turn signal light on the dash stay on which would cause it to yell at me after a while letting me know my turn signal was still on when it wasn't. I have replaced the bulb socket on the front driver and upgraded to LEDs since the stock bulb size isn't very bright and I do a lot of night driving.
After doing that, a few days later, I had an issue with my instrument cluster not lighting up when I turned on the headlights. I looked it up and guesses were a bad fuse or the relay in the multifunctional switch in the steering column. I replaced the fuses, and nothing happened. I ordered the relay to be delivered the next day. Later that night, I had my headlights on and then parked somewhere, turned them off and when I came back out to leave, I started my Jeep, smelt something weird like an electrical fire but didn't see anything. My headlights were no longer working and the dial on the switch wouldn't stay in place when turned. I had high beams, but I had to hold the lever back. (not fun for the 20 min. drive home)
I went home and ordered the switch. Once relay and switch arrived, I installed them and when installing found that the plug on the left side of the switch was burnt and need to be replaced. Ordered that, spliced it in and headlights worked. Turn signals and taillights were still a no go and no instrument cluster lights.
So currently, I have headlights, brake lights, and dome light. No instrument cluster lights/dash lights, taillights, turn signals or hazards. If I turn the hazards on, I have no brake lights. While braking, the turn signals have a dim flash on the dash if turned on and do a single flash in the taillight. Some forums I read said I might need resistors due to the amount of stock lights replaced with LEDS (headlights, taillights and side markers are all LED) but I'm not sure what exactly I'd need. I have tried replacing the turn signals light with the stock bulbs and still no lights. Also, within the past week I have a new engine code P1687- "no cluster bus message" according to the Jeep repair manual I found in a forum on here for my model year. Any thoughts?

Second problem,
On Tuesday, I was driving home from work and was about 20 minutes from home when my Jeep decided to start making some awful noises in the front and rear and started feeling like she was struggling to keep momentum. I pulled over at the next exit and got out to inspect. I crawl under and the rear diff was smoking. Both my diffs have had a slow leak for a long time. The front is the pinion seal and the rear is the bolts aren't the right size for the aftermarket heavy duty rugged ridge diff cover, so the seal isn't perfect. I check all fluids every week to make sure all her leaks aren't going to cause issues. I just moved so my mind has been crazy, and it must have slipped my mind to check the past week or two and so the rear diff was empty. I had a bottle of gear oil and dumped it all in. Let it sit for a few minutes to get the oil in and then started on my home. I got to the other side of the rest stop and got to about 5 mph before she started making the noise again, but it was only in the front. I backed her up, drove forward and did that a few times trying to figure out where the noise was coming from. I can't tell if it is the front diff, wheel bearing or ball joints (which I know need to be replaced soon). I couldn't tell what was wrong so I called my dad, and he couldn't figure it out and at this time it was late enough it was pitch black so with the abovementioned of no taillights or hazards we came to the conclusion that I need to call AAA. She drove onto the tow truck and off but has not and will not be moving until I figure something out. Any ideas on where to start?

I am hoping someone might have some ideas before I drop a bunch of money diagnosing.
 
RE the electrical issues. Id check every ground there is. Unbolt, sand or to clean where they are landed. Jeeps are rusty things and corrosion will cause resistance, which will cause heat and melted wires as you describe. Far as the diffs go....You ran the 35 out of oil, its likely damaged beyond use and in need of a potential complete rebuild or at least bearings. The front diff, hard to say if it still had lube in it. Pop the covers off and look at the R&P and spiders, spin the wheels and pinion, its all very likely done unfortunately. I had a set of the covers with bars or ribs if you will. The circular part that sits to the cover fit like crap, and like you see caused leaks. Pull them, grind or bevel in inner edge as needed to fit flat all around the covers.
 
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Pull the front shaft- cardan may be failing.

That Jeep needs some tlc it sounds like.
 
Turn signal light on dash with headlights on would most likely be down to a bad ground at the headlamps. It could also be bad bulb or socket in the front turn signal.
No marker lamps or dash, combined with no stop lamps should mean no power to fuses 1 and 2 behind the glove box. Power to those fuses is supplied by a fuse in the under hood Power Distribution Center (PDC). Can't tell you which fuse without knowing model year. If whichever fuse it is is good, there could be a wiring issue between the two fuse boxes.

I see you have a manual though. Go to section 8w-01 which explains how to read the wiring diagrams and see if you can work it out. If not post back.
 
Novak Conversions Jeep Wrangler TJ engine mounts