If I was frustrated by people doing their best to broaden their knowledge, I wouldn't have participated in this thread. I've had some awesome mentors, starting with my father, and maintaining vehicles is a dying activity. I like doing what I can to keep that spirit alive!
I can't tell from the picture, but looking at the pin out for C154, that section of the harness should have threeofor four (more on that next) wires in it - one or two Black wires, one Violet with Black Stripe wire, and one Violet with White Stripe wire. Here's that pin out from the FSM:
View attachment 536143
I'm with you - if the black wire was broken, splicing it should have fixed you issue. The black wire is in the ground path for starter relay coil.
Side note - it seems that everywhere you turn, you're finding problems with that TJ. You've got your work cut out for you!
That's still seems like too much resistance to me.
I looked into that a bit yesterday. Go back up and look at the C154 pin out above. Notice that, for a manual transmission, both pin 1 and pin 3 are the BK wire. I believe that you'll find that one of them goes to G105, and the other goes to the other pin - like a Daisy Chain. That said, I have no way of determining why that is. I also have no way to tell what happens if that jumper (between Pin 1 and Pin 3) is broken. Test resistance from Pin 1 to G105 and then again from Pin 3 and G105. Also do it for Pin 1 to Pin 3. Report back with results.
In addition, you should pull all of the wiring from C154 to the break you repaired out of the loom and inspect it. Is there a short black jumper wire between Pin 1 and Pin 3?
S134 is a splice, not a connector. Harness section #3 goes from the PDC's starter relay socket to Connector C104. Splice S134 is located here:
View attachment 536151
Keep doing the yeoman's work. First, let's make sure your meter leads aren't finky. What's the resistance when you touch the red probe to the black probe? It should be 0.1 or 0.0, depending on the meter. If it's higher than that, we have problems.
Second, my suggestion is pull everything out of the looms to inspect it. Compare wire colors to a study of the wiring schematics. The way the schematics work, it's not easy to do that because there is no actual diagram of the wiring harness. You're looking to confirm that no one has screwed with the harness and for obvious damage, like that broken wire you found. Then you can use the resistance measurements to try to pin-point the source of the high resistance. Everything should be a dead short, or 0.1 ohms. Anything higher than that means something is wrong.
Thank you again!
Okay, staying positive. I'm going to slow this down and do it right. One step at a time. Starting from the beginning. G105 to C154.
G105: I took both eye rings off, sanded both sides of both, sanded the nut and the bolt, and reassembled.
C154: I de-loomed everything from G105 to C154. I can confirm that the broken wire only had one place it could go. It was the black wire coming out of the connector, and it went to the broken black wire in the loom. The other three wires are in good shape. Those are violet/white, violet/black, brown/light blue. Those wires are all connected correctly (I'll add pictures to this post once I post, as I edit and add pictures from my phone).
I checked every inch of the black wires and the brown/light blue wires from G105 to C154. I cannot find any break of any kind. I think I see S132 (the splice of ground wires in the picture). That all looks good too.
I touched the leads of the multimeter together and got a 0.00 reading.
I used a jumper wire pushed into the pin with the black wire in C154 and ran it up a lead from my multimeter. I ran other other lead to the ground bolt at G105. The multimeter read 0.4 ohms when on the 200 setting.
I'll stop there for now and see your thoughts so I don't get ahead of myself with any next steps. If that is too much resistance, I'm not sure what is wrong because I can't find any issues with the ground wire between the two points.
Side note: There seem to be so many inconsistencies in the FSM. It has the brown/light blue wire listed as an auto trans wire. But that's been labeled as the manual trans wire elsewhere, and you can see in my harness it's there. This was a manual trans Jeep from factory.... So strange.
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