Topic: 1994 with no-start problem

[DanMarino]

OK, my YJ just started acting up.  It is a 1994 with the 4 angry squirrels and the AX5 transmission.  I went to the mall over the weekend with my 77 year old dad to get some dinner.  When we returned to the Jeep, it wouldn't start.  It acted like the battery was dead.  It seemed like there wasn't enough power for the battery to crank the starter.  I waved down the mall security vehicle and they hooked up a jump box to the battery.  After a few  minutes, the YJ still wouldn't start.  Ended up doing a push start and it fired right up after popping the clutch.  The 4 squirrels ran fine on the drive home and the alternator was charging the battery to around 15 volts.  The alternator and battery are about 12 months old.

So last night I pulled the battery.  Voltage was 12.8 or something like that.  Since the battery had a 2 year warranty I took it back to Advance Auto Parts and they checked it with their load tester thing.  It had something like 550 cold cranking amps and tested out fine.

So any advice on what to check now?  I put the battery back in and tried to start the YJ and no go.  My son observed that the starter is trying to start the engine and the serpentine belt is creeping along very, very, slowly...like barely moving.

Thanks for the suggestions.

13

[neale_rs]

You may want to suspect the starter motor.  I would probably get a new battery just to avoid problems.

[Jeffy]

Yeah, I'd suspect the starter.  I'd at least have the starter tested.

[DanMarino]

OK so how do I test the starter?

[DanMarino]

I watched some youtube videos.

1.  I have 12 volts getting to the starter.
2.  I jumped the connection between the starter solenoid and the 12 volts on the starter using a screwdriver.
3.  When jumped, I got sparks.  I also got a humming noise and it sounds like the starter is barely turning.  Humming, noise.  No start.  Just creeping inside with a resistance sound.

So I'm thinking the starter needs to be replaced.

[DanMarino]

A rebuilt/refurbished starter from Advance Auto Parts is around $70.  A brand new starter is around $150.  Any reason I shouldn't buy the rebuilt/refurbished starter?

[Jeffy]

I'd go with a rebuild unless you can get a deal on a new one.  Rebuilds have lifetime warranties unlike some new stuff.  Any of those parts stores should be able to test your starter for free, too.

[DanMarino]

Bad news.  I stripped the external torx head on one of the starter bolts.  There is a transmission bolt that is in the way of my socket extension on the starter bolt that is closest to the middle of the Jeep.  I can't figure out what size bolt for the transmission.  None of my sockets/wrenches worked on it.  If I remove the transmission bolt, maybe I can get the socket on the starter bolt head better.  Stupid design.  E-torx stinks.

[DanMarino]

So I think I'm using the wrong terminology. 
Looks like there is a dust cover for the clutch opening that fits onto the bell housing.  There is a big bolt there that I need to remove because it is in the way of me removing one of the starter bolts.  Anyone know the size of the bolt head for that cover plate?

[neale_rs]

Not sure of the bolt size but it's standard either SAE or metric, I've taken those off several times.  Or just use an adjustable wrench, it shouldn't be too tight...it's a big bolt but it just holds on the dust cover, maybe put some penetrating oil on it too make it easier.

[Jeffy]

So I think I'm using the wrong terminology. 
Looks like there is a dust cover for the clutch opening that fits onto the bell housing.  There is a big bolt there that I need to remove because it is in the way of me removing one of the starter bolts.  Anyone know the size of the bolt head for that cover plate?

That's called the inspection plate.  Two big bolts hold it on IIRC.  I think they're M8 but no idea on the pitch.

[DanMarino]

Problem solved.  New starter is on the YJ.  I removed the big bolt that holds that dust plate thing onto the bell housing.  I ended up using adjustable wrenches on that big bolt and nut.
I got a set of E-torx sockets and used that on the starter bolt that was a little stripped.  I heated the old starter and bolt up for a little while with a propane torch, then hit it with some more PB Blaster.
YJ started right up.  There is no reason for those starter bolts to have that stupid external torx head on them.  Dumbness by Jeep.

[neale_rs]

Glad to hear it is working now.