Hey Dudes!

Ok I came out of the store today with my son hopped in my jeep, turned the key, all lights were normal but no starter. I haven't had any issues with the jeep in a while its been running like a top. Well I checked a bunch of stuff while in the store parking lot but nothing. Finally my son asked me if I could just hotwire it which gave me an idea. I turned the ignition on, pulled the starter relay and jumped the contacts with a paperclip. The starter cranked and the old Italian oil crusher burst to life. I hoped in and drove us home without incident.

Once home I turned it off and tried to restart. The same thing, all seemed normal but no starter crank. I swapped the starter relay for the one next to it to figure out if it was that, it wasn't. I put a multi-meter on the relay coil contacts and there was no voltage with the key turned to start. I check the other fuses in the box and they were good.

I would appreciate any suggestions.

Please keep in mind that because I was able to start it by jumping the relay I don't think it is one of the transmission interlocks (park brake). But...homestly I don't know, which is why I'm here.

I suspect the ignition switch itself does anyone know how to verify?
Are their wiring diagrams available?
I'm being led to believe there is a switch in the transmission that may also crap out to cause this.

While your reading this I will be actively searching, diagnosing.

Thanks I look forward solving this.

Hmmmmmm? I found this. It could be. If only I had the T10 security bit. I'll try to make one.

If you have a Harbor Freight nearby, I found one there for $7 when my switch broke.

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2005 Liberty CRD
2004.5 Cummins 5.9L TD, F1s, NV5600 6-speed in a '93 GMC Suburban

Thanks msilbernagel I've already got that as the first stop tomorrow.

In order to get around until I get this fixed I wired in a momentary switch. To do so I simply yanked out the starter relay, wired the switch to one end of the wires and soldered the tabs from a standard auto fuse to the other. Plugged the tabs into the starter side of the relay. Now push the button for starter. Tucked the wires back and bingo works great.

I'm still going on a hunch that its the ignition itself, if anyone has anything else to suggest I'm listening. Thanks.

As you stated in your next post....the actuator that turns ignition switch is broken. There are so many cases of this happening on all of the KJ forums that we need to open a Sticky on this problem.

The main thing is to follow the different leads on where to buy the actuator assembly...the Dealers do not stock it and insist that you have to buy the complete steering wheel assembly

Your fix with fitting a switch in the Starter Relay Socket will work fine....otherwise you can remove the ignition switch off of the actuator assembly and turn the switch with a small flat screwdriver....you need to remove this switch in any case to see if the actuator tip has indeed broken off and this will prove if the ignition switch itself is working.

By jumpering pins 30 and 87 in the Starter Relay socket you have completely by-passed the interlocks such as transmission in Park, transfer case in Neutral etc. so there is still a possibility that there is a problem there....turning the ignition key with a flat screwdriver will clear up that issue.

The ECU basically has little to do with the starter solenoid getting power...the Starter Relay Interlocks basically interrupt the negative side of the Starter Relay Energizing coil....you can download the relevant year KJ Service Manual here...includes the circuit diagrams: http://www.colorado4wheel.com/manuals/Jeep/KJ

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2002 Export CRD 2.5 Sport

Thanks for the post Billwill. I have already ordered the ignition "Dorman 924-704 Ignition Switch Actuator Pin for Chrysler/Dodge/Jeep". Made by the same people that made the video posted. I ordered it from Amazon.com for $27.06 (http://amzn.com/B004BYX8W8). If it turns out its not that I'll just return it. (I'm not sure if its available to you in SA).

I will verify the switch failure once I get the to needed security tool.

Thanks for the wiring diagram link, it doesn't appear to work though. If you have any knowledge to diagnos the other failure possibilities I would appreciate it.

Thanks again

Correct link for manuals is http://colorado4wheel.com/manuals/Jeep/KJ/

gmz105 - if you can catch up with your Amazon part order they have a torx security bit set for like $8

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

Hi Billwill I discovered the typo in your URL, the "m" in "com" is missing.
http://www.colorado4wheel.com/manuals/Jeep/KJ/

Thanks again!

The latest status: I got the T10 security bit this morning. Disassembled as per the previously posted video. Its pretty close to it. I restored the starter relay then pushed the plastic piece and turned the ignition with a screw driver, it started. So I am still assuming its this. I couldnt remove the Ignition Switch Actuator Pin housing as they did in the video. I will wait until the part arrives before I start forcing things apart, you know just in case.

Anyone have anything else I should try?

Thanks.