Seems to only happen when heat soaked, but it's NOT overheated by any means. Sometimes, I turn the key, hear the relay click, dash lights dim just a bit (like normal), but it won't turn over. Starter is new as of 30k miles ago. I do notice quite a bit of drawdown on the volt meter, bring the needle down the the exact half mark. I haven't tested to see how much voltage is actually getting to the starter yet, but it's very strange to me. Turn the key a few times, when it does engage the starter, it fires off great. No sluggish turn over. Practically starts with a bump of the starter.

Ideas?

My theories would be wiring, because of the drawdown, possibly the 20+year old ignition switch, and lastly the starter.

Any experiences would be appreciated.

 

I had to install a 4 pole relay to fix my problem. something about the ignition switch not shooting enough juice to engage the starter. pretty simple fix, if that is your problem.

 

See below for some testing tips:
- http://www.4crawler.com/4x4/CheapTri...shtml#EasyTest

And here are some fixes if you find low voltage at the starter solenoid:
- http://www.4crawler.com/4x4/CheapTri...l#OtherOptions

 

Thanks, fellas. Sounds like a cheap enough try. I'll do this.

 

An aside: I have a 30 amp relay laying around the garage. Any reason not to fab my own "Hot Shot" kit?

 

Sure, give it a shot.