Originally Posted by MattMansXJ007
My 1998 XJ was running fine then cold hit & bout 5-7 days ago started slow cranking. & thought was cold starts then went from almost didn't start at gas station to won't start at home, this past Friday on Black Friday, guess that's good time as any in a way lol. Anyway it's not even turning over really it was then stopped & just made click so figured ok starter motor or drained battery so since the battery sucked took out to test also but it actually was drained but not bad but had only 520 crank amps & was a refurbished or st, so decided changed out & put a yellow top deep cycle in. Then tested starter & the motor was fried or solenoid fried. So got new one & changed out.
But when I did I noticed a sheet in new starter that said 1996 XJ had a Mega Fuse that was design flaw by Chrysler & they've said to change to fusible link, did they fix that on XJ by1998? Mine doesn't have mega fuse just a wire ontop another wire but does look like it might if had one? So I'm confused there. Also when I went to put on new battery the + cable cane out in my hand! So looked at it & the guy has spliced in a 4ga cable into the factory red + cable for some reason & idkif if he did bcuz of that or WTF is going on.
So I installed starter & wired back fuse enough for connection to check new starter & it cranked right up so I figured ok I can get a new cable & replace it do washed up & cane out & when turned it over it started to but then stopped, & made weird noise again like it slow started but then just killed? I tried to turn it again & the lights & all went off again like b4 when I thought battery was dead but know that optima is brand new do not it, so "safely" lol squashed cables together to c if connection or st, & lights came on when tried to turn over but making clicking noise like strayer is out again! So wtf is my jeep blowing the solenoid or did get bad part or is the + cable BS causing it all &/or bcuz of Mega Fuse? I'm stumped & really don't wanna pay my shop to fix an electrical gremlin or st that could really rack up shop labor hours & parts!
PLEASE anyone that knows what's going on with my jeep or had similar problems, please let me know st. Thank you
OEM circuit protection for OBD-II vehicles is using a segment of 10AWG fusible link wire in the OEM 6AWG lead. The MEGA fuse was not used as OEM on the XJ - the only fuses were in the OBD-I PDC, where a pair of MAXI60 fuses was used.
However, retrofitting a MEGA fuse (adding a stud on the other tab of the PDC baseplate) is a common mod, and worthwhile.
If that fuse has been eliminated, I recommend that you replace it ASAP. It's there for a reason!
The stud on have two wires on it from the factory - a feeder lead from the battery, and the alternator output lead. The starter motor lead is separate.
Where was the 4AWG lead spliced in? From the battery, or from the alternator? If it's from the alternator, you need
to replace the fuse (whether you get another stud for a MEGA fuse, wire in an ANL fuse holder, or replace the OEM 10AWG fusible link wire - which you have to get from the dealer, so far.)
A "clicking noise" when starting has a couple of potential causes, in your case:
- Failed/failing starter motor solenoid contacts (the plunger pulls in & the drive pinion kicks out, but current does not flow to the main motor.)
- Failed/failing starter motor relay (in the PDC - but it's a much quieter "click.")
- Failed/failing primary lead between the battery and the starter motor.
- Failed/failing starter motor mounting (power comes IN on the mains lead. It grounds through the mount screws & pad. If it comes loose, it may not get full current flowing through it, and that may not be enough to spin the motor. Even without a load, you're still looking at 160-180A to spin the thing!)
I am assuming that the clicking noise is coming from underhood, so we can draw the inference that the ignition electrical switch (atop the column, down by the firewall, I believe) is still okeh.