Quote
But the motor would not crank and starter wont kick in

is that related?


Are you ABSOLUTELY SURE the noise comes from inside? The starter is right there on the outside of the firewall and a noise from it can sound like it's coming from the kick panel. I re-read your post a couple times. I think you'd be best off checking out the starter and solenoid before tearing into the wireing and control units. I've had starters make a 'buzzing noise' that sounds like it's coming from inside the cab and had the same thing happen as you describe.

'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD