Gr8Dain's 4.0/aw4 swap from a 97 XJ

[gr8dain]

Thanka.

Thanks. And yeah, I noticed that some were not the right amps. I will replace those.

 

[FLCJ8]

Thanks. And yeah, I noticed that some were not the right amps. I will replace those.

I read in another post that you had a fuse blow. Did you determine why?
There is a possibility that this could be related to your ASD relay issue.
Maybe you could remove all the fuses that are not needed for the engine to start and see if the relay reacts appropriately. If so, replacing one fuse at a time could help locate the problem.

 

[gr8dain]

I read in another post that you had a fuse blow. Did you determine why?
There is a possibility that this could be related to your ASD relay issue.
Maybe you could remove all the fuses that are not needed for the engine to start and see if the relay reacts appropriately. If so, replacing one fuse at a time could help locate the problem.

Well the fuse that blew controlled the radio and I put the power ports and the radio into the same BS blank spot for the radio in the bottom corner of the fuse block. I assume it popped because of that. But not sure since the radio never turned on so not sure if it was drawing power.

As for removing fuses and trying one at a time is worth trying. Thanks.

 

[gr8dain]

Since I moved vehicles around the driveway, I decided to take the Scrambler for a short test drive. Of course I still had to jump the wire in the ASD relay ports. But I did drive it. I did not go far or fast. Kept it under 15 mph. It did fine. I am not sure I even got to second gear. Maybe I shouldn’t have at that speed. I will test that out later.

What did I learn? I think my parking pawl is broken. It doesn’t stay still in Park. It rolls and clicks. Hmmmm.

Working with the guy that built the harness tomorrow. Fingers crossed.

Oh and to prove to the HOA that it moves, I parked it in a backed in manner.

 

[gr8dain]

Talked to Hotwire this morning (builder of my harness). We went though some tests. The thought is that the ignition feed from the bulkhead is not connected to the correct pin in the fuse box in the harness. As the voltage at the fuse drops to zero when the key is turned to start. I will be tracing that ign power wire (position 172 on the firewall connector) to see where it goes, as it does not appear to flow into the blue/white wire going to the start/run fuse in the new fuse panel.

Getting closer, I think.

 

[bigwalton]

Talked to Hotwire this morning (builder of my harness). We went though some tests. The thought is that the ignition feed from the bulkhead is not connected to the correct pin in the fuse box in the harness. As the voltage at the fuse drops to zero when the key is turned to start. I will be tracing that ign power wire (position 172 on the firewall connector) to see where it goes, as it does not appear to flow into the blue/white wire going to the start/run fuse in the new fuse panel.

Getting closer, I think.

Was there a test to check to see if there was power at the correct bulkhead location in the engine bay side of things as it sits now? I would want to confirm that before you chase anything else on the Jeep side since things were working prior to this swap.

Or am I misunderstanding and you're saying you're tracing the wire on the harness they modified? Maybe I'm misreading when you say "does not appear to flow into..."

I read all of this as something in their harness is wrong, so it's not a matter of what flows into it, it's what's not flowing through it.

 

[gr8dain]

Was there a test to check to see if there was power at the correct bulkhead location in the engine bay side of things as it sits now? I would want to confirm that before you chase anything else on the Jeep side since things were working prior to this swap.

Or am I misunderstanding and you're saying you're tracing the wire on the harness they modified? Maybe I'm misreading when you say "does not appear to flow into..."

I read all of this as something in their harness is wrong, so it's not a matter of what flows into it, it's what's not flowing through it.

Correct. He thinks the wires are set up incorrectly in the harness. The run/start circuit is currently only hooked up to a run power source. So when cranking in the start position, no power is making it to the ASD circuit. So I will be tracing the wires within the new harness that is commected into the original bulkhead connector.

He says it is an easy fix. I just need to find the wires. It was difficult to do some of it over the phone with him. But progress was made. He was shocked that I am able to get it to run with the jumper wire.

 

[gr8dain]

I talked to Hotwire again today. Based on pics I sent him of the bulkhead wiring (from the replies in this thread, so thank you all), he thinks he knows what wires got mixed up in the harness. So I am going to disconnect the engine side, and get it back to him to fix. It is a bit of a hassle, but glad they are dealing with it. I asked him why he had done two for a friend (Rick Milam) without issue and he said he did not know. I suggested that they look through the notes for his harnesses before sending mine back.

 

[bigwalton]

I talked to Hotwire again today. Based on pics I sent him of the bulkhead wiring (from the replies in this thread, so thank you all), he thinks he knows what wires got mixed up in the harness. So I am going to disconnect the engine side, and get it back to him to fix. It is a bit of a hassle, but glad they are dealing with it. I asked him why he had done two for a friend (Rick Milam) without issue and he said he did not know. I suggested that they look through the notes for his harnesses before sending mine back.

Good deal that they’ll sort it. Seemed like it just had to be something off they did on the harness to me.

 

[gr8dain]

Well, the harness came back last night. So O installed it this morning and it fired right up. Woot!

Now to register for the national scramble........

 

[gr8dain]

I really wish I could post a video here. Oh well.

 

[bigwalton]

I really wish I could post a video here. Oh well.

Too much burden on our servers to render the video. YouTube links work great.

 

[gr8dain]

Too much burden on our servers to render the video. YouTube links work great.

Yeah. I figured. I just need to use my youtube account more I guess

 

[gr8dain]

While I am chasing my tail to figure out why it started on Thursday but now won’t send voltage to the starter, my Barnes 4WD crossmember/skid arrived today.

Somit will sit in the garage a bit while I troubleshoot. I thought maybe the ignition switch went bad. Popped in the spare. Nope. Maybe NSS? Will check. I checked the fuses. Found the one out that kept my fuel gauge and temp gauge from working. So little victory.

Oh well. I must love working on this Jeep.

I am committed to the Nationals, so this had better run by then.

 

[gr8dain]

Jumped the NSS and it fies up. Grrr. I guess I will be running to the store to pay $279 for a new one.

 

[Belizeit]

NSS = ?

 

[FLCJ8]

NSS = ?

Neutral Safety Switch

 

[barrys]

$279....ouch. how much at rockauto?

 

[gr8dain]

$279....ouch. how much at rockauto?

It was less but days away. With my son’s employee discount at Advance it was about the same cost though. Thank goodness my boy works there. This was 20 some years old. I will probably take the old one and try to clean/repair it and keep it as a spare.

 

[Randyzzz]

It was less but days away. With my son’s employee discount at Advance it was about the same cost though. Thank goodness my boy works there. This was 20 some years old. I will probably take the old one and try to clean/repair it and keep it as a spare.

I’ve never seen a NSS that was that much. Can I you post a pic up just to satisfy my curiosity?