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intermittant not starting #714594 04/10/06 09:56 PM
Joined: Mar 2004
Posts: 152
Mike_Pirie Offline OP
Wheeler
Hi all,
I don't post here much, but follow the forum and value your opinions.

Here's the problem: Once every month or so, the starter does not turn at all when attemting to start the truck. When it does not start, it may not turn over at all for 10-20 turns of the key, then all of a sudden, it starts right up.
I have replaced the starter, and cleaned and tightened all battery connections. This problem happens when cold and fully warm. The starter never cranks slowly, its either a perfect start or nothing at all.
Is there a relay or something I can check in between the switch and starter that may be the problem? Maybe a relay or ?

Thanks for the help.


1992 montero, cranked t-bars, OME springs, 1-1/2" spring spacers, Homemade rear bumper and roof rack, 33" BFG AT, 1" body lift, Superwinch hubs, '95 SR locking rear axle, was AT - now V5MT1-3 5spd.
Re: intermittant not starting [Re: Mike_Pirie] #714595 04/10/06 10:02 PM
Joined: Jan 2000
Posts: 16,227
off-roader Offline
Web Wheeler
*****
Neutral safety switch in the transmission shifter may need cleaning or need to be replaced.


Off Roader
98 Montero with the Winter Package
89 Montero minty clean and reserved for overlanding trips or Cars and Coffee events
96SR (3.15:1 xcase, 35's) gone to the rust gods
96SR Build Up Thread
Old web page
Old web page
Re: intermittant not starting [Re: Mike_Pirie] #714596 04/10/06 10:06 PM
Joined: Feb 2005
Posts: 509
W
Winston Offline
Rock Warrior
My money is on the key switch. You can replace the electrical portion of the ignition key without changing the mechanical portion of the key. Dealer part, but not too expensive. Common problem.


'90 Montero XLS (Sold, sadly)
'95 Montero LS 160k
'03 Montero Limited 30k
Re: intermittant not starting [Re: off-roader] #714597 04/10/06 11:33 PM
Joined: Mar 2004
Posts: 152
Mike_Pirie Offline OP
Wheeler
Where is the nuetral safety switch? In the shift culumn somewhere?


1992 montero, cranked t-bars, OME springs, 1-1/2" spring spacers, Homemade rear bumper and roof rack, 33" BFG AT, 1" body lift, Superwinch hubs, '95 SR locking rear axle, was AT - now V5MT1-3 5spd.
Re: intermittant not starting [Re: Winston] #714598 04/11/06 12:43 AM
Joined: Nov 2002
Posts: 7,892
stony-man Offline
Web Wheeler
*****
Quote
My money is on the key switch. You can replace the electrical portion of the ignition key without changing the mechanical portion of the key. Dealer part, but not too expensive. Common problem.


we've replaced it TWICE on our '95...first time I got one from a salvage yard, last time got a new one from the dealer.

Re: intermittant not starting [Re: stony-man] #714599 04/17/06 05:55 PM
Joined: Mar 2004
Posts: 152
Mike_Pirie Offline OP
Wheeler
Well, I tried to find the neutral safety switch this weekend, but had no luck. My manual is very vague about where the switch is. I know now that it is not in the center console area (I think Gen 1 was in console, but not Gen 2).
Is the switch down on the transmission near where the cable connects? Can someone describe the location?

Thanks


1992 montero, cranked t-bars, OME springs, 1-1/2" spring spacers, Homemade rear bumper and roof rack, 33" BFG AT, 1" body lift, Superwinch hubs, '95 SR locking rear axle, was AT - now V5MT1-3 5spd.
Re: intermittant not starting [Re: Mike_Pirie] #714600 04/18/06 11:51 PM
Joined: Sep 2004
Posts: 178
V
v6lsmonty Offline
Wheeler
Ignition switch is about $25. You might also go for the "clicky starter fix" do a google search. There are kits available for about $12 or you could fab your own. It bypasses the switch and zaps the starter directly from the Batt.


1989 Montero LS (sold)
1994 Cherokee Country bone stock
Re: intermittant not starting [Re: v6lsmonty] #714601 04/19/06 12:12 AM
Joined: Mar 2004
Posts: 152
Mike_Pirie Offline OP
Wheeler
Thanks v6lsmonty, I may put in a direct battery start switch as a backup in case I have future problems.


1992 montero, cranked t-bars, OME springs, 1-1/2" spring spacers, Homemade rear bumper and roof rack, 33" BFG AT, 1" body lift, Superwinch hubs, '95 SR locking rear axle, was AT - now V5MT1-3 5spd.
Re: intermittant not starting [Re: Mike_Pirie] #714602 04/19/06 03:38 PM
Joined: Feb 2005
Posts: 509
W
Winston Offline
Rock Warrior
Have you found your problem? Did you check the ignition switch?


'90 Montero XLS (Sold, sadly)
'95 Montero LS 160k
'03 Montero Limited 30k
Re: intermittant not starting [Re: Winston] #714603 04/19/06 05:27 PM
Joined: Mar 2004
Posts: 152
Mike_Pirie Offline OP
Wheeler
I have not found the problem yet. It has been starting just fine for a couple weeks now, so it's hard to do any diagnostics. Since I can not easily find the mysterious "neutral safety switch", then I probably will change out the ignition switch this weekend and see if the problem continues.


1992 montero, cranked t-bars, OME springs, 1-1/2" spring spacers, Homemade rear bumper and roof rack, 33" BFG AT, 1" body lift, Superwinch hubs, '95 SR locking rear axle, was AT - now V5MT1-3 5spd.
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