Hey all! I have an interesting problem I am having trouble diagnosing and thought I'd put it out into the forum to see how the group does!
Info on van: 2006 Dodge Sprinter 2500. approx 260,000 miles.
Recent work (done by myself so please consider any potential issues that I may have caused..):
-Removed and tightened bolts on high pressure fuel pump
-New Starter
-New fuel filter
-New battery
-Terrible rust around windshield to the point of no replacement possible. So Duct taped around the windshield to prevent leaking into the cabin..
All of these were over 5K miles ago
Problem statement:
I had a no start condition about 6 months ago. Traced it to the electrical starter system (turned key with interior lights on and saw dimming). When I checked the electrical system wiring, I found that the ground strap was very corroded. I cleaned it up, along with the ground points next to the strap and the ground points next to the battery. Car started right up. I ordered a new ground strap and installed it. All good for about 2K miles.
Then the problem happened again. No start. Thought it might be the battery, but the battery had a full charge. Though it also appeared to have a parasitic drain. Roughly 150mA. Traced the draw to the instrument cluster fuse (#13) under the drivers seat. When I removed the fuse and turned the key, the instrument cluster started flashing super quickly, so I assumed there was a crossed wire somewhere. Removed the cluster and cleaned the connections, never really found an obvious cross. Also cleaned the ground points near the battery terminal again. She fired right up. Good for about 2K miles.
Then the problem happened again. Decided to just clean the ground terminals near the battery and she fired right back up.
So it appears that the ground point near the neg terminal of the battery has some problem. Though it seems odd to me that it keep corroding enough to not start the car? It is possible that the resistance at this point throws current back into the instrument cluster causing it to flicker? Could resistance at this point present as a parasitic draw?
Any ideas about solutions would be super helpful.
Thanks in advance
Jason
Info on van: 2006 Dodge Sprinter 2500. approx 260,000 miles.
Recent work (done by myself so please consider any potential issues that I may have caused..):
-Removed and tightened bolts on high pressure fuel pump
-New Starter
-New fuel filter
-New battery
-Terrible rust around windshield to the point of no replacement possible. So Duct taped around the windshield to prevent leaking into the cabin..
All of these were over 5K miles ago
Problem statement:
I had a no start condition about 6 months ago. Traced it to the electrical starter system (turned key with interior lights on and saw dimming). When I checked the electrical system wiring, I found that the ground strap was very corroded. I cleaned it up, along with the ground points next to the strap and the ground points next to the battery. Car started right up. I ordered a new ground strap and installed it. All good for about 2K miles.
Then the problem happened again. No start. Thought it might be the battery, but the battery had a full charge. Though it also appeared to have a parasitic drain. Roughly 150mA. Traced the draw to the instrument cluster fuse (#13) under the drivers seat. When I removed the fuse and turned the key, the instrument cluster started flashing super quickly, so I assumed there was a crossed wire somewhere. Removed the cluster and cleaned the connections, never really found an obvious cross. Also cleaned the ground points near the battery terminal again. She fired right up. Good for about 2K miles.
Then the problem happened again. Decided to just clean the ground terminals near the battery and she fired right back up.
So it appears that the ground point near the neg terminal of the battery has some problem. Though it seems odd to me that it keep corroding enough to not start the car? It is possible that the resistance at this point throws current back into the instrument cluster causing it to flicker? Could resistance at this point present as a parasitic draw?
Any ideas about solutions would be super helpful.
Thanks in advance
Jason