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02 TJ that wont crank

642 views 5 replies 2 participants last post by  RUBI 4 MY MRS 
#1 ·
The weather finally broke enough to want to take the Jeep out but it wount start. After a poor diagnosis I ordered a starter and pushed my Jeep into the garage. After it did not fix my problem I looked into the problem alot closer. I have narrowed it down to the 30 lead losing 12v when you try to crank it over. in other words you can jump it at the relay. I can feed 12 to the output side of the relay and get it to start and stay running. under the dash the pink and black has 12v on it until you go to start it then it drops out. I'm guessing its a corroded wire but wanted to know if someone else has had this.
 
#2 ·
You may be in luck (somewhat). That pink/black wire goes from fuse 6 in the PDC to the starter relay (terminal 30) also in the PDC. It also splices & goes to the ignition switch but that splice is either under the PDC or in the harness not far from the PDC. Since you are losing power to the relay the bad spot has to be at or before the splice. First pull the fuse & make sure the 2 legs are not corroded & that both fit tightly into the socket. If good, lift the PDC & check that wire especially at the fuse end crimp. Look for corrosion & wiggle it around. Also check the wire for any damage to the insulation. If good so far you may have to trace it to the splice & check that for corrosion too.
 
#4 ·
It has been a long time since I had mine out but you definitely have to get to the under side to see the wiring.

Not sure exactly where the splice is. All it says in the FSM is “Near T/O for Battery Temperature Sensor or Power Distribution Center” & looks to be along the side of the PCM near where the battery sensor wire comes out of the main harness but the manuals are not always too exact on these things & it would make more sense to be under the PDC since one leg goes to the relay which is right there. Of course they don’t always use the best common sense when designing these. If the wire from the fuse leaves the PDC & goes into the harness & a different wire (same color) comes back in & to the relay you will have to follow those 2 to where they are spliced in with the one that goes on from there up to the ignition switch.

Still it’s more likely to be at or near the fuse.
 
#5 ·
Fixed!

I FOUND IT!!! I unwrapped the harness right where it goes into the PDC. That harness had been rubbing on the bracket it had previously said it was snagged on. The wire in question was "swollen" and had a pin hole with green powder coming out of it. It was easy to spot. I'm happy I got it taken care of. The jeep needed a new starter anyhow. Thanks for your help. It gave me the confidence to get it done and was just the push I needed to get this problem solved.
 
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