Gremlin! Seek & eliminate!

[ChefClay]

UPDATE - Called out the RAC home service this morning. After well over an hour, isolated the problem to the cable between the Starter Solenoid and the ignition. Only 5v reading initially to this connection. (Black cable with feint white line) Battery, Starter, Earth & Power leads checked & all ok.
Please that he got me this far, where do I go from here!! Do you suggest an auto-electrician or is it something I can tackle myself? - Thanks for all your comments by the away, really appreciated, Paul.

 

[mickmonk]

I'd see what voltage you have got comming out of the ignition switch, it still could be corroded contacts in the switch. I cant remember what colours wires go to it but if you have 5 volts on a cable with the ignition switch fully turned on then thats your problem.

 

[ChefClay]

Hi mickmonk,
The switch was replaced last week, so hopefully that will not be the problem! The RAC seemed to think there was a problem in the actual lead from the ignition to the starter.
Cheers, Paul

 

[extreme-4x4]

but you have changed the starter, was tis new ? did it come with solenoid or did you use your old one ...

it will be the solenoids or the main live feed from battery to starter usually is

im right in thinking the switch has been changed ... so that eliminates that .......... dont it ???

 

[clivvy]

if RAC man thinks it might be the solenoid cable, i assume he means the one you have to unplug to remove the starter?if so, is it fitted ocrrectly, or are you saying you may need to replace it, can you see any corrosion? bit awkward that cable isnt it?

 

[danielj]

yes, its dead easy to do, just atough awkward hence why MIckMonk used a ratched with drive bit in it, thats what i did-space is tight but you hardly have to un screw the screws to get it free-dont loose them!

While it looks like it won't help Chefclay with his problem I did have a look at my ignition barrell last night. Took of the covering around the steering wheel and disconnected the connectors going onto the ignition barrell set-up. Gave the insides of the connectors a few scrapes with a paper clip and then sprayed the connectors with contact cleaner. Have started the truck about a dozen times since and worked fine first time each time. So maybe it was only a dirty or loose connection on mine.

 

[clivvy]

While it looks like it won't help Chefclay with his problem I did have a look at my ignition barrell last night. Took of the covering around the steering wheel and disconnected the connectors going onto the ignition barrell set-up. Gave the insides of the connectors a few scrapes with a paper clip and then sprayed the connectors with contact cleaner. Have started the truck about a dozen times since and worked fine first time each time. So maybe it was only a dirty or loose connection on mine.

i'd say thats good to try, i find with these trucks silly little things such as a bit of grime cause serious problems!

 

[ChefClay]

Thanks for the advice. Just to go over again, Starter replaced (Hitachi for a Bosche), ignition switch replaced, power lead from battery to starter replaced, earth-leads checked & cleaned, battery ok. Going to clean inside those ignition connectors (danielj - post). Started ok today 3 - 4 times, 5th time took 20mts! Just when you think you've cracked it!! - Paul

 

[clivvy]

Thanks for the advice. Just to go over again, Starter replaced (Hitachi for a Bosche), ignition switch replaced, power lead from battery to starter replaced, earth-leads checked & cleaned, battery ok. Going to clean inside those ignition connectors (danielj - post). Started ok today 3 - 4 times, 5th time took 20mts! Just when you think you've cracked it!! - Paul

somethings still not ringing right for me. when I did my ignition switch, it worked just liek for you, 4/5 times ok, then not after that, then random, after that, it was the starter for definate, fitted a brand new one and everythint was mint. so with that in mind, it does still sound liek a dirty connection or dodgy wire somewhere around the ignition..?!

 

[iandouglas]

Dinky had problem with his old mav when he stopped at the meeting place for one of the lane days North Yorkshire moors I think it was.
he tried to start but nothing past ignition ON sorted by turning key all the way then easing it back until it made contact with starter ,
suspect contacts burning out in switch.
had same problem with a new JCB that week.

 

[bailey]

non-start

i have had the same sort of faults on my maverick , problems started with a poor engaging starter,
fitted a new starter , would start 3 or for times and would not start after

after many hours of checks found that the wire from the ignition switch to the starter had gone black about 8 inches up the wire causing voltage drop , sometimes getting 12 volts and other times 8 - 9 volts. cut this wire out and soldered a new one in,
the other fault i found was that when i fitted the new starter motor was that i was loosing the earth on the starter due to rubber seal on the bell housing-engine . i added on extra earth to the starter motor to body , now starts fine

 

[ChefClay]

i have had the same sort of faults on my maverick , problems started with a poor engaging starter,
fitted a new starter , would start 3 or for times and would not start after

after many hours of checks found that the wire from the ignition switch to the starter had gone black about 8 inches up the wire causing voltage drop , sometimes getting 12 volts and other times 8 - 9 volts. cut this wire out and soldered a new one in,
the other fault i found was that when i fitted the new starter motor was that i was loosing the earth on the starter due to rubber seal on the bell housing-engine . i added on extra earth to the starter motor to body , now starts fine

Hi Bailey - after months of trying to find the reason for intermittent starting, the problem was finally solved yesterday by a local auto-electrician!
The wire that was showing the low voltage return like yours, was replaced with a heavier gauge wire. Starts first turn every time!!!
He explained that between the ignition and the starter, the cable had to overcome various switches & junctions, this resulted in the reduced voltage. Therefore, sometimes it started, other times it did not!
I was that close to selling the Troll I was that fed-up with not being able to start it and even worse, nobody being able to come up with a solution!
All's well now in the camp, ironic that your thread appeared within 24hrs of rectifying the same problem. Wished you had have seen my thread 3 - 4 months ago!!

Just to thank all the other members who gave their time to suggest what the problem was,
Cheers - Paul