98 Jeep zj with a 4.0. This Jeep has been to hell and back. Lots of miles and issues.... Trying to keep it going for a little longer. I replaced bcm because of faulty original with internal short. Fixed the drain. Rebuilt alternator, starter and new battery. Cleaned every connection as well. Now only starts with a jump start. Starts right up and will drive fine. Park it and try to start it again and nothing. No power anywhere. Battery is fine. My next fix will be the battery cables and clamps. Any thoughts?
I hook the cables straight to the post on both. I think the battery cables are original and I can see green corrosion where it goes into the wire shield. Its just weird that nothing comes on when I turn the key. No lights, gauges, nothing....
I had the same problem when I got my ZJ. It had a new alt and battery. After noticing the hammer marks on the starter, I replaced it. Still would not start without jumping. Voltage guage was all over the place. While cleaning the battery terminals again, I noticed the body ground was rusty and neg cable corroded (green). I replaced both cables cleaned the grounds and added a extra ground from firewall to the engine/ starter bolt.
Every thing now works great! Starts instantly, no more misses at idle. My non-working windows and door locks now work and gauge holds steady at 14 volts.
Yes. The cables on a ZJ split off in a few different directions! If possible buy OE cables! These things are really finicky about the electronics. I had to splice and solder the Negative cable. It comes off the battery terminal in two wires, one to the body, the other goes down to the block, but also splits off to the alternator with a special connector.
There is one on Ebay, looks like crap, but you can see how the cables run. # 261178514480
I added the extra body ground out of habit, I've owned a lot of Fords!