Failed to crank over after NSS wire wore down?

Tiny
MONTYTRAX
  • MEMBER
  • 2000 MITSUBISHI MONTERO
  • 3.0L
  • 6 CYL
  • 4WD
  • AUTOMATIC
  • 240,000 MILES
A transmission rebuild shop left the transmission harness loose to wear against the driveshaft. SUV failed to start after NSS wire wore down and the 40-amp Ignition fuse blew out. The starter was working fine before this but now won't fire. Tried jump-starts from working engine and a fully charged jump box. Neither worked.

I do hear the solenoid clicking when the key is turned. Is it possible the starter was damaged by the electrical shorting (either through the NSS or other damaged wire)? Are starter rebuilds a good option in this situation or is it better to replace it with a completely new part?
Wednesday, December 11th, 2024 AT 9:51 AM

5 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,313 POSTS
I good quality rebuild is a good choice, but it might not be the problem, did you repair the wiring? I would check to make sure the starter solenoid trigger wire was getting power when the key is in the crank position. Here is a guide to help you test it:

https://www.2carpros.com/articles/starter-not-working-repair

It is the small blk/blu wire at the solenoid. Here is the starter wiring diagram so you can see how the system works. Check out the images (below). Please let us know what happens.
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Wednesday, December 11th, 2024 AT 1:28 PM
Tiny
MONTYTRAX
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Thanks so much for your reply, Ken. Yes, the NSS wiring was repaired, at least to the point that the truck would start. The shop that replaced the 40-amp fuse fixed the NSS wiring so that the starter would fire. And after this the starter would sometimes start but also fail intermittently: sometimes it would only fire after 2-3 cranks (silence otherwise), sometimes I'd have to let engine cool for the starter to fire.

Is it incorrect to conclude that if I hear the starter solenoid click once when I turn the ignition key that the solenoid trigger wire is getting enough power? I'll need to check it later when I have a voltmeter to know if it has the necessary 12V.

At this point, the battery should charge, but the Rally 2-amp maintainer connected as in the photos, doesn't indicate either it is charging or that the battery is bad. I tried several different connection points to get a good ground with the same result. So, there seems to be some other electrical issue.

I very much appreciate your assistance.
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Thursday, December 12th, 2024 AT 12:32 PM
Tiny
KEN L
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You need to connect the negative side of the battery charger to the battery, not the cable.
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Thursday, December 12th, 2024 AT 6:15 PM
Tiny
MONTYTRAX
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Yes, but the instructions for this Rally model say not to connect the charger directly to the negative terminal. If the battery is installed, the negative lead is clamped to the chassis, engine block, or other ground; but that setup wasn't working so I disconnected the leads and tried to get a ground through the negative cable.

It's working now. With the battery uninstalled, the negative lead gets clamped to a 24 in. (Minimum) 6AWG lead wire connected to the negative terminal (instructions photo - Step 5 in the “Uninstalled” section). The charging indicator is on now (see photos).

If the truck still doesn't start after topping up the battery, I'll check the starter trigger wire voltage. Thank you, Ken.
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Friday, December 13th, 2024 AT 2:24 PM
Tiny
KEN L
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Okay, that looks better, let me know what you find with the starter trigger wire.
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Saturday, December 14th, 2024 AT 10:14 AM

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