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[patg]

One year back when I went to start my Cherokee 98 2.5 diesel all appeared ok as for instrument panel lights but the starter failed to work. The solenoid could be heard to click as the key turned but that was it. After speaking to dealer and finding the only way to the starter was to drop the gearbox out was not to impressed so checked out battery posts removed leads and cleaned all. It then started fine, and for next 8 months only for the problem to return in winter and cleaning leads or posts made no difference as did a new battery. The fault was intermittent often starting in the morning getting me to work but not home without a jump start. It was often hard to jump start. I fitted a second earth lead from the battery to the engine block and the problem once again stopped. Now 4 months later the problem has returned. It failed to start in the morning then with nothing being done it started first time on my return from work! It will start a number of times one after another but then leave it a few hours and it will not start. Any ideas or am I going to have to bite the bullet and pay £500 to have the gearbox out just to check the starter! 
     

[wildrover]

Don,t be pulling the gearbox out just yet.....

I have a feeling it might be something else other than the starter...

An expert will be along any moment to tell you....

[Mike Pavelin]

Gearbox out? Bollocks. The o/s engine mount has to come off though.

[patg]

Thanx Mike         Been having a look and can see how to go about it now. True to form though it's now starting first time every time! Still going to have a look at the starter and wiring though. Then maybe wire in a push to make switch on the dash to give a work around circuit.

[Dave69]

give the associated electrical contacts a clean

[patg]

The problem returned and I was able to get it to start by locking and then unlocking making me think it's an immobiliser issue. Then the next time the only thing that got it going was a jump start. So at the moment i'm back to thinking solenoid/starter wiring but I would like to disable the micro switch under the clutch using the yellow bypass jumper taped to the main harness if I could find it!
     Update: I can see the black wires running from the switch and these go into a green connector block with small red tab, out of this run 2 yellow wires to the harness. Just how does this come apart??  

[Mike Pavelin]

Remove both the battery terminals, clean the posts on the battery and inside the terminals.

[patg]

I've done that Mike the last time it failed but no good, yet it started straight away when my mate turned up and we jumped it. 

[patg]

[attachment=1]

Attached is pic of connector, the just visable black wires on the rear go to clutch micro switch these look like they come out as are in black plastic connector but how do I release them? I'm thinking the red tab is the answer but how to release it ??

[Panic mechanic!]

if i remember correctly you pull the red tab and it releases the lock then it should pull apart

[patg]

Must admit I've given it a good pull and it's not moved! But then it's been there since 97! After looking at the pic full size on a large monitor it seems there maybe a lug in the middle of the red part that needs pressing with a small screwdriver as you pull. No doubt would have it apart in a few mins if in my hands on the bench but with my head in the footwell under the pedals, reaching up under the dash working by torch light is a bit different!

[GREGBLACK]

Hi mine  has been doing this off and on for a bit about a year to be exact, If i move the wiring harness to the starter at the back of the engine it usually starts straight away I just give it a wiggle  , sometimes someone has to operate the starter when I do this. I think its a bad or dirty connection to the starter solenoid or possibly the ignition switch, it usually gives most trouble in our local tesco car park I don't know what that's about but I now shop at asda and it hasn't happened there yet.
 

lol greg

[patg]

Well the micro switch on the clutch is now disconnected and the feed shorted. It's been 17 days since the last failure but soon it's up on the ramps again and the starter is coming off then going to a local guy to be checked out, while I check all the wiring out. Mine seems to have no problem with supermarkets as I visited Tesco, Asda and Sainsburys yesterday with no probs! Just seems to fail in the carpark at work! lol  Anyone know of a link to manual for 2.5TD as would like to download one but cannot find a link that works. 

[carljh]

http://www.scribd.com/doc/19477634/vm-25-manual

[patg]

Thanx for the link .  Only failed once in the last 8 weeks and moving the wiring harness appeared to work cheers Greg. Had starter motor off yesterday checked all connections and tested wiring found nothing. Put a direct wire from solenoid round to near battery giving the option to dab it on the live to start. It started fine a number of times in the workshop ok on the key but upon leaving I had to dab the new wire on the battery to start! On my return home it would not start on the key or wire, same the next morning then left it for an hour only to have it start on the wire and the key. New starter on way and back up on the ramps tommo!