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It seems to be a common problem I was wondering if anyone has done the zook fix (wire in a relay and get power straight from the battery, instead of through the key-switch) on a montero and if it is a similiar problem to begin with?


I don't know about a "zook fix", but yes, I have added an additional relay switch and Bob Shaw has. After burning up two starter solenoid switches I suspected low voltage was the problem. I was told by an automotive electrical rebuilder that the Bosch solenoid switches are prone to failure due to low applied voltage. There are about a dozen electrical connections in the circuit from the battery through the ignition switch and on to the starter solenoid switch, which to me is a problem waiting to happen and over time it will. I tested my solenoid feed and got various readings that ranged from full battery voltage down to as low as 8.5v - not good. I suspected the ignition switch and replaced only the electrical part of the switch (about $20), then added in a standard automotive solenoid switch that is triggered by key-switched voltage, but when triggered throws power directly from the battery to the starter solenoid switch. Since making the modification I've had zero problems. If I have a problem now, it's more likely to be with the added relay which is easy to replace, costs only $8 and it's available at any auto parts store. Here's a picture of where and what I mounted:
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I like the Ford-style relay - it will not blow with low voltage like the Bosch unit and if it does, there's less work and money to replace it - it makes for a good way to jump/bump the engine too... like an installed remote starter switch. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Frank


'89 [color:"white"]G-Raider[color:"white"] [color:"black"]Supercharged 3.0L, MegaSquirt 2, lockup A/T, 2.5" exhaust, 172k, Cibie H4s/Oscar SCs, Hella Micro DE fogs, Cobra CB, Superwinch hubs, LSD rear/Aussie Locker front, Bilsteins, Lifeline AGM, Rust-Oleum