burning wires at starter relay
Today i go out and start up the jeep like everyday to warm up a little. I come back inside after shes idling good, after about 3 or 4 minutes i hear it shut down. All at once, no sputter no hack... just like i turned the key off. I go back out and hit the key, nothing at all. The key buzzer sounds and the headlights turn on but thats it. no blower motor no dash lights no nothing accept that stupid buzzer and lights. So i start poking around under the hood to see if i can find a indication of the problem. I find a burnt wire at the starter relay, the insulation was split off for 3 inches and the wire had broken from the heat. So just to check out if that was the problem i twisted the wires together and had someone try to fire it up. Vroom Vroom. right away she started and runs fine, all the bells and whistles are working again, for an instant.... Then i see that same wire start to heat up and burn again... like glowing red, melting off the insulation.
This burn started about 4 inches before the wire goes to the starter relay, and continues to burn twards the relay. The wire is green and it goes from the relay, (as a green wire) comes to a joint(looks like a rubber cylnder connection) at the wiring harness on the firewall, then comes out that joint as a red wire and goes into the harness. The connection the burnt one makes to the relay is the only one connected to the lug that is a 'pigtail'. Meaning there is one connection made to the relay, but 2 wires coming from that connection. all the other wires to the lug have a independent connection to it.
So what i am wondering is what this wire goes to. As i said its the only connection to the lug that has 2 wires coming from 1 connection (tied together before contact) so hopefully someone will know what the 2 tied together go to, and then i will have a 50/50.
Also i am wondering if the starter relay is what is causing this problem, at first i was just settled on bad wire, but then i read a post made by jeephammer and in it it says that the starter relay is what keeps the high amperage from going into the wiring harness/fuseblock/ignition that is suppose to go to the starter.. or at least that is what i gained from it. So using that lodgic, i thought that maybe the relay stuck in a position after starting the jeep that caused the high amps to go into that wire, inturn melting it down.
I really hope that someone can give me a little insight on this one. As i am scared to replace that relay, and replace the wire, making them the strong point and then the melt down happen somewhere not so easy to work.