My '05 TJ, 6 cyl, 6 spd tranny , 73k miles, has always run great. However, went to start her the other day and NOTHING! Battery checks good. When you turn key to on position all lights, radio, blower fan, all work fine. But when I turn key to cranking position, nothing happens. No solenoid chatter or anything. Got under it and tapped starter and solenoid with a hammer but that didn't help either. Could it be the switch that keeps it from cranking until clutch is depressed? Anyone got any other ideas? Thanks!
That would be my first guess........I THINK (not positive) that it should kinda "click" even if switch isn't tripped...but am not positive. GOOD LUCK!!
Clutch Interlocking Ignition System
Manual transmission vehicles are equipped with a clutch
interlock safety feature. With this feature engaged, you
must depress the clutch pedal to allow cranking of the
engine. To temporarily bypass this safety feature while
off-road driving (4L range only), which will allow crank-
ing the engine without depressing the clutch, follow
these steps:
1. Locate the Power Distribution Center (PDC) in the
engine compartment. Refer to “Fuse Panel” in Section 7
of this manual.
2. Put a 10 Amp fuse in the PDC cavity (#28) marked as
Clutch Override.
NOTE: A fuse is provided in fuseblock cavity (f19 or
f20) marked as Spare.
3. Be sure to re-engage the clutch interlock safety feature
by following these steps in reverse order when you are
finished off-road driving.
Set your Ebrake, turn key on, make sure gear shift is in N.....put the fuse back in Swamp guy was talking about...and jump across the starter with screw driver.
It should might spark and crank....if it doesn't might be ahead to get starter checked like they are saying.
Generally though, IMO if you hit the key and everything is "working" 'cept starter you will "feel/ hear" the drain on the battery....are you hearing anything when key is turned?
Finally got baack around to my TJ's problem again today. Maybe some of you "Techies" can answer this. Today, I removed the starter relay in the underhood fuse box. Put a volt meter in every socket relay plugs in to. Found constant 12vdc at one socket. Put meter probe in every other relayblade socket, one at a time and turned ignition switch to start position. No other socket showed any voltage when I turned key to start each time. So, that seems to me to confirm that its probably the ignition switch that's the problem. Would this be correct? Thanks!
The most likely problem is a broken actuator pin tip. The only way to tell is to take it apart. When apart you can see if the pin is broken & you can turn the switch with a screwdriver to test the switch & the rest of the circuit. If it starts with the screwdriver you can at least drive it to get the actuator pin which is not available from the dealer, only parts store or on line. You will need a security t-10 Torx bit or you can break the security tab off with a small punch or even a common nail & use a standard bit. There is only 1 bolt holding the ignition switch on to the actuator assembly & with that removed you can slide the switch off & see the actuator tip (without removing the whole assembly). Be careful not to bend the flexible rod that goes into the switch. Here is a link with good photos of that & a u-tube video of removing it.
Photo of broken pin tip & of assembled cylinder, pin & switch TJ won't crank
OK, back for more advice. Pulled ignition switch and disassembled it. No broken pieces fell ut and nylon actuator pin doesn't appear to be broken. It sticks out from it's holder approx. 1/2 inch. Comparing mine to pic of a new actuator pin assembly on Dorman's website, it looks exactly the same as their new one.
Anyone know if this is the length of an unbroken pin?
As advised above, turn the switch with a screwdriver in the slot to see if it starts. If it does you will know that the key is not turning the switch far enough to get it to the start position. Then either its a key cylinder problem (not likely) or the tip is broken. They all seem to break the same way. (see the photos in the link).
If turning the switch doesn't get it to start, the problem is elsewhere.
Did try with screwdriver and NOTHING! My actuator pin appears to be same length of all those I've seen in videos and on websites like Dorman. Looked at it with a magnifying glass and I'm just about positive nothing is broken on it. All smoth, nice rounded edges, etc. So, putting it all back together and towing it to the shop where the pro's can hopefully get it fixed.
Thanks to all for your replies and good advice.
Oldchief, "Living the dream here in the Ocala Nat'l Forest"
Next chapter in my never ending ignition switch nightmare.
So, today I put all ignition components back together and everything fit right together and buttoned up just fine. Tried to install lock cylinder and it almost goes in all the way, but not quiet...maybe 3/16" from fully seating, so the little latch pin on bottom won't go in it's hole in the cylinder housing. I've followed all instructions on the several "how to" videos on the web, have switch and key in "on" positions.. damn thing just won't go in that last little bit. I'm about ready to try a large hammer.
Any suggestions/ideas? Thanks!
Another chapter in my nightmare! Neighbor and I are trying again to get lock cylinder to seat properly and all of a sudden, the actuator assembly flies apart. We managed to locate all the parts EXCEPT the little spring that holds the little brass locking tab thingy. Search all over Jeep, inside and out, even with magnets (but it may be stainless). Couldn't damn spring anywhere. So, I order a new assembly for $39. Haven't tried to install it yet but noticed that installation instructions that came with it differ somewhat from those you see on the YouTube videos. So, at this point, it isn't installed. But, a word of caution for those going thru this process. Whether you're installing a new actuator assembly or putting old one back in, BE VERY CAREFUL HOW YOU HANDLE IT, or you'll be hours hunting that damn little spring. I guess we could have substituted it with a similar spring but I opted go go for a new assembly, since old one looked OK and I'd have used it, if spring hadn't been lost but, since actuator pins have a propensity to break anyway, figured might as well suck it up and get new. Sure hope next install try is successful and I don't lose another spring!!!
Once you get the actuator assembly fixed you are back to it not engaging the starter, right?
Before you button it all back up you should test the ignition switch. With the connector plugged into the switch check if the pink/orange wire gets power when you turn the switch all the way to the start position (with a screwdriver). If not & being sure the radio & turn signals work with the switch in the on position, the switch is bad. If you do get power to the start wire but not to the relay socket which should be to the 86 terminal or possibly the 85 then you have a break in the wiring between the switch & the relay.
Finally got ignition switch all back together yesterday. Everything comes on and works but still no power to starter. But, now the new wrinkle is, the right turn signal won't shut off. It's like the multi- switch is jammed. Don't think I damaged it when I moved it out of the way to work on ignition switch, but maybe I did. Will try to figure it out today. Last 2 multi-switches I bought from Mopar didn't work right in my Jeep...no turn signals or 4 way flash, so returned both of them. Sure hope I don't have to order another new one. Have about concluded this job is above my paygrade, so will probably push start her and take her to a real mechanic.
Earlier this afternoon I went out and figured what the hell, worst case, I'll have to order a new multi-swtich So, I forced the turn signal lever down. There was a pop noise and right turn blinker went off. Tried right again and it worked like new. Left also, so for now, it seems to be fixed.
JKP, we've tried and tested everything. All tests good. There's a good well recommended mechanic across the river from me, so will get it to him sometime this week. Thanks!
Your ignition key is not gray is it? Those have an anti-theft system.
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