Re: Starter, no start - possible melted yellow wire - Saab 900 Bulletin Board - Saabnet.com
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Re: Starter, no start - possible melted yellow wire
Posted by JohnK (more from JohnK) on Sat, 23 Jun 2007 15:14:15
In Reply to: Starter, no start, turbocon86, Thu, 21 Jun 2007 10:53:33
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It doesn't take long for the thick yellow unfused wire, from the ignition switch to the starter, to melt its insulation and that of other wires in the harness. That could be why the other electrical problems have popped up.
The fix is to unwrap the harness and repair the bad wires. Tape up the wires where the insulation is gone and rewrap the harness. To get at the harness you must remove the driver's seat, console, knee bolster, and then peel back the carpet to expose the harness. It runs along the shifter tunnel up to the firewall above the pedals to the bulkhead connectors.
The 29 pin bulkhead connector can also melt, but usually just where the yellow wire connects. With a bit of luck the rest of the bulkhead wire connector contacts will be OK. If so, you can run a new and separate "yellow" wire from the ignition switch directly to the starter solenoid connector on the starter. Run it along the harness and find a grommet in the firewall and stick the wire through it and lead it over near the brake master and then to the starter. Tie wrap it so that it doesn't hang up in the belts which are close to the firewall.
If you are experienced pulling the seat, console and knee bolster, you can do the whole rewiring job in a Saturday morning. If not, figure a whole day. Better to split the job over a weekend, since you will get tired and perhaps a bit sloppy. This job is not difficult, just very tedious. Good luck.
After rewiring, I guarantee that you will always be sensitive to the position of the ignition switch. BTDT.
posted by 69.249.52...
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