Starter trouble

[ivegot2legs]

New member, long time Jeep wrencher.

I’ve had a 2006 Wrangler 4L manual since it was new. Recent trouble starting it up.

A few years ago, I replaced the ignition cylinder, actuator, and relay, since the actuator was broke. Also replaced the starter a bit later.

Recently it was having trouble starting. Sometimes just a relay click and no engaging of the starter. So I again replaced the cylinder, actuator, and ignition relay. Also replaced the battery, cables, connections, and starter. Tried a new starter relay with no change.

Despite all this, sometimes turning the key will click the relay and nothing else. One or two more tries, and it starts up fine. So it will start, but not without trouble.

I’m wondering if this is related to the clutch safety switch or clutch linkage. It’s the original clutch (133k). The clutch friction point has gotten lower over the years, but it shifts fine.

How do the wear components of the clutch affect the safety switch and starting circuit?

I’ve considered just using a push button starter but I’d rather not overlook a safety and functional issue with the clutch. I’m at the end of the components I can replace in my driveway.

 

[TheBoogieman]

I'd have the "few years" old starter checked first. It's free.

 

[GaTechTJ]

As the clutch wears, the point it grabs changes. This doesn't usually effect where it is when pushed all the way in to release.

That said, the switch can go bad. You could unplug the wire to the clutch switch & use a wire to jumper across the wires to see if that eliminates your problem. (The switch is normally open and closes when the clutch is pushed.) The switch is on the shaft on the clutch pedal that goes through the firewall. Switch is on cabin side of firewall.

 

[JustDandee]

I recently noticed that there is a fuse location (engine compartment)on my 05 that seems to allow for a clutch over ride. Never had the owners manual but threw a fuse into it and it would start without using the clutch. Something to try for kicks and giggles.

 

[ivegot2legs]

It was the clutch interlock safety switch.

Starting was intermittent. When it would crank, it would start fine. Which made sense because I replaced all the other starting components.

When it would not crank, it would activate the starter relay only.

A fuse in #28 for clutch override fixed the problem, but then 4WD light was always on.

I cut off the clutch safety switch and tied the wires together, works fine now.

 

[JustDandee]

It was the clutch interlock safety switch.

Starting was intermittent. When it would crank, it would start fine. Which made sense because I replaced all the other starting components.

When it would not crank, it would activate the starter relay only.

A fuse in #28 for clutch override fixed the problem, but then 4WD light was always on.

I cut off the clutch safety switch and tied the wires together, works fine now.

Forgot about the 4wd light being on, which was why I pulled the fuse. Glad you found the culprit!