HELP! Charging problem on 89 Cherokee

I'm currently having charging problems with a 89 Cherokee 4.0 4WD. At 150k miles this thing has decided it wants to charge the battery sometimes and other times it doesn't, here's a list of things I've tried:

- New alternator (twice)
- New battery
- Checked all the fuses under the dash (there's only a relay center under the hood)
- Checked wiring between alternator and solenoid
- Checked wiring between battery and ground/battery and relay
- Checked wiring between relay and alternator
- Checked the grounds for the alternator, battery, solenoid and starter
- Belt is in excellent shape and isn't slipping.

Neither my Hanes manual or the local parts stores break-downs show an external voltage regulator or ECU that could cause the trouble I'm having but obviously something is being overlooked. When it runs it runs like a scalded dog and when it doesn't all the lights, wipers ect will all but cease and it will spit and sputter until the battery is completely drained then it will struggle to run and not restart if it dies - the solenoid wont even click. I'm thinking it's one of two things but I'll be damned if I can find it:

1) There's a bad connection somewhere in the charging system.
2) Something is intermittently shutting off the flow between the battery and alternator.

A few other bugs on the list I don't feel are related are:

- Fuel gauge is pegged straight down (I noticed a fuel theft had occured shortly after this issue started, I figure the thiefs hose snagged and bent the gauges float assembly).
- No instrument lights except dash back-light.
- Left turn signal always solid green, right turn signal solid green when activated, neither one blinks.
- The blower fan works intermittently regardless of setting.
- Factory radio doesn't work.
- Horn doesn't work.


Note: The year before last I replaced the clutch slave cylinder after it blew out and shot fluid through a slot in the firewall and dripped into the fusebox.. the fusebox was cleaned, dried and ALL of the fuses replaced.

Thanks for your help,
William

My guess would be that there's a break in the wiring somewhere. It won't show in most wiring tests because contact exists while it's sitting still, but the virbration cause while driving causes it to intermittantly lose connection.

I had a similar problem once & only found the culprit by literally breaking down every component.

I'd try changing out the wiring between the relay and alternator.

That's where I'd go next, anyway. Good luck!

- Rafe

[xjy173]

Welcome to the board!!


I'm thinking you have a intermittant dead short somewhere in the wiring, probably the insulation is rubbed off somewhere and when it touches the metal body of the Jeep, you get a tremendous battery drain that the alternator cannot keep up with. My '86 XJ had the main power wire and the ground running down to the starter in the same wire loam. It was factory run very close to the passenger side exhaust manifold (it was a 2.8L V-6 engine). The heat from the manifold eventually melted the insulation from the wires and they touched. When they did, I lost everything but the good news was by then it was REAL EASY to find . You may have a similar problem.

Your dashboard devices have a common ground strap that goes from the firewall to the engine block. If it is corroded or frayed, that would might be the cause of your dashboard trouble. The constant lit left arrow light could also be sign of a ground problem; another device has found a path to ground thru the arrow light.The turn signal flasher may also be bad, as well. To find the culprit circuit, remove fuses one by one. When the left arrow goes out, you'll know which circuit it is. That might cut down on the troubleshoot time.

Good Luck!! Let us know what you find.

[NIX]

If everything dies at once, it must be a common cause like a power cable or groundstrap. Check the ground from the loom that's attached tot the dipsticktube at the engine block and chack the strap that goes from cilinderhead to firewall. By checking I mean disconnecting it (not a cilinderhead bolt!!), cleaning it and taking of rust or other crap and mounting it carefully back again with some acidfree vaseline or something else protectant. Also check cables for internal breaks.

I broke down and started yanking wires today, here's the list and outcome for each:

Main fuse block: A little goopy from the factory electronics jelly, seperated and cleaned all three pieces then replaced all of the fuses - Did NOT solve the problem but everything looks nicer now.

Common ground on drivers fender: Corroded connectors, screw and fender surface. Sanded and remounted - Corrected ALL of the instrument lights, indicator lights, turn signals, radio and fuel gauge.

Starter relay on passengers fender (9 wire junction): Corroded connectors and terminals. I stripped all five wires from the main post on the relay, sanded all of the mounting surfaces, pulled apart and cleaned all four wire terminals and remounted them all after making a new hot wire from the relay to the positive battery terminal - Corrected the charging issue along with the intermittent heater fan.

Horn: I was out of luck on this one, the internal button assembly is totally FUBAR and requires replacement - Works out for the best anyways, I hate that mammoth steering wheel so I'll swap out the whole thing.

I hope my torment helps someone else with their troubles. Thanks for your input and suggestions guys!

William

[NIX]

Glad you got it fixed.