No crank, no start. 97+ AW4

This just happened clear out of the blue over the last few days. It started with hearing the starter getting hung up when starting (grinding noise), to taking a few tries to start. Here we are a few days later, and nothing.

Where we're at: Newer battery, newer starter (verified good), new power wires (.6ohm over the whole length). Starter relay was swapped into a different spot and works. Fuses all look good (maxi and mini). JUST replaced the ignition switch. No change. If you put it in to reverse, you get backup lights. Tried jiggling shifter and trying to start in neutral, nothing.

Any ideas?

-P

I always suspect the most recent repairs/upgrades, and cheap Chinese parts. Recheck all the work for loose connections, chafed or melted insulation on the wire harnesses, and corrosion or pushed back wire pins in the wire harness plugs.

Rebuilt starters (and alternators) are very often poorly rebuilt, especially the ones with a "Lifetime Warranty". Round up the usual suspects and have them bench tested indoors. Handheld testers are inaccurate and will often pass marginal batteries (and alternators).

Once you have the basics all covered, bypass the NSS and see what happens.

Tim_MN said:

[...]
Once you have the basics all covered, bypass the NSS and see what happens.

Click to expand...

Went back over everything. No dice. Bypassed the NSS, started. Removed bypass, no start.

Have the switch open right now, looked kinda nasty. Cleaning it up and going back together in the AM.

Thanks for the help!

-P