Electrical Woes--SSDD

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Joined
Sep 8, 2004
Threads
34
Messages
242
Location
Orygun
Hey Folks:

I've been nursing an electrical/starting issue for quite a while now--you may have seen some earlier posts. I've still got issues, partly because I'd rather get kicked in the nads than do electrical troubleshooting. Here's my full story, and I sincerely appreciate any advice you can provide.

Equipment:
13BT in an FJ60
12 Volt starter
12 Volt alternator
No significant wiring changes to original harness.

Symptoms:
1. every once in a while I'll go to start, all gauges light up, but when I turn the key all I get is a click--a single click. Sometimes when this happens if I turn the key enough times it will finally turn over and start. Sometimes not. When this symptom happens the voltmeter is often sitting right at 12. I installed a dual battery (painless system) setup as a backup, and MOST of the time I can get it to start with both batteries connected. Sometimes even this doesn't work, sometimes it works right away, sometimes it takes a few turns of the key before the starter engages, and even when both batteries do start it up it isn't like it roars to life.

2. Sometimes when the start issue occurs, I get no reading on the voltmeter for the main battery, but 12 volts if I click to both batteries. Sometimes when this occurs, if I hold the key in start long enough (on the main battery), all of a sudden the voltage registers, but it still won't turn the starter, and it occasionally registers but then drops back to zero.

3. When it is running, I can watch the voltage dip when I use any accessories (wipers, lights, etc).

4. ALL OF THESE SYMPTOMS WERE PRESENT PRIOR TO AND AFTER THE DUAL BATTERY INSTALLATION


What I've done:
1. Tested both batteries with a multi-meter. Both consistently register at about 12.45 volts.

2. Inspected and cleaned all leads to and from both batteries, with the exception of the lead from the negative pole to the engine block. All grounds have been removed and reinstalled. In some cases this has allowed me to start the vehicle, sometimes with just the main but sometimes it requires both batteries.

3. Removed aftermarket stereo connection to ignition thinking there might be too much draw.

4. Inspected starter contacts for wear--they look brand new.

5. inspected, removed, and reinstalled starter ground and battery lead to starter.

6. punched several objects in my garage.

What say you?
 
Inspected and cleaned all leads to and from both batteries,with the exception of the lead from the negative pole to the engine block.

What say you?

:rolleyes:Thats where I would have gone 1st. I had a similar problem with my old 3F and when I checked the lead where it bolts to the block the copper lead had gone green and was badly corroded.
It doesnt matter how clean the battery leads are if the other end has high resistance.;)
 
Thanks, Roscoe.

I will check it out, and hope that you're right. I am worried that the resistance is coming from somewhere in the wiring harness to the ignition. We'll see.
 
Checked out the lead to the block. Clean as a whistle.

I'll be checking cable to connector contact tomorrow. Any other thoughts greatly appreciated.
 
Thanks for the tips guys. My issues are still happening. I've narrowed it down to either the ignition circuit or the starter/solenoid circuit. The problem is that it only happens intermittantly, and even when it happens once it may start the on the second try.....very difficult to test.

My solution as of now is to bite the bullet, get a reman starter, and see what happens. If it continues to occur I guess I'll replace the ignition/starter switch.
 
electrical issues

Sorry to hear of your woes, I know how frustrating it is.

I have had a variety of elec issues with my 79 BJ and though perhaps some of my journey may be useful. I would recommend checking your ignition switch. I'm not sure of what the set up on your truck is, but mine has a little white housing on the steering column (under the plasic covers) that connects through to the key tumbler. I found that the intermittent problem came from worn copper contacts inside the little white plastic housing. If you do decide to investigate inside this switch housing, I recommend doing it inside the house.....lots of little pieces inside that go 'sprong'.

Don't know if it applies to you, but might be another place to check.

:cheers:
 
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