On Monday, August 28, 2023, 6:44 PM, Carl <cbilter@xxxxxxxxx> wrote:
--Yesterday I drove the J up to Mopars on the Mississippi in Dubuque, IA, and it ran and drove great – until – about 2 minutes from my destination, when suddenly and without warning, a terrible noise began emanating from the engine compartment. Sounded like a really bad water pump, but temp. gauge good. Noticed the ammeter pegged on charge – electrical malfunction – with no place to pull over I briskly made a mad dash to the show, pulled in and pulled over, shut the ignition off, removed the key – starter motor kept running!
Fortunately, I had a ½” wrench in the console (ALWAYS carry one), popped the hood, removed the negative cable, assessed damage. Nothing visible, but bad burned rubber smell. Quickly determined it must be a stuck solenoid or bad starter relay (that turned out to be wrong). Our buddy Noel came over with a spare starter relay, which I installed, no change. Fortunately, local buddy and long-time member Dave Schwandt was able to come out with his 3500 Dually and his son’s trailer, and we loaded up the J and took it back to Cedar Rapids.
Diagnosis today – took all of 3 minutes – positive battery cable from the starter relay to the starter motor, insulation burned right through, battery cable and solenoid wire then shorted, starter engaged continuously. This was a reproduction cable from the Inc. 300 Club, with no heat shielding. When I installed the cable I purposely made sure it was a couple inches away from the header. It ran near the heat pipe, but that wasn’t the issue. Evidently, on a long run, the header gets so hot that it was enough to melt all the insulation. I had heat wrap on the shift cable, as that had been damaged long ago due to running over the header, but didn’t wrap the repop battery cable.
Lesson: cable MUST be heat wrapped, or do NOT use the Inc. club repop cable Note: Quirey now reproduces the proper cable I believe; Jamie can confirm. The photo below shows the damage – see lower center of photo. This cable is NOT sitting against the header, but it still burned.
Carl B.
Older and now wiser
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