96 XJ won't turn over

Hi everyone!

I've searched through the threads and can't seem to come up with a solution to my problem...

I was driving my 96 XJ on the highway a few days ago, pulled into a store parking lot and shut it off (to go into the store). When I came back out, it simply would not turn over. This is very frustrating to me since I just went through this a few months back. At that time, I read all the posts about the Neutral Safety Switch (NSS), cleaning it replacing it, etc. I initially tried cleaning the one on the XJ, still didn't make it go. Went ahead and bought a new one and installed it, still no go! Then got the bright idea to check voltage at the solenoid on the starter with someone turning the key to the start position - WOW! There was voltage at the small solenoid wire, I tapped the solenoid and it fired up! One new starter and it was all better.

Meanwhile back at last Saturday: Knowing I have a brand new NSS and starter, I thought it to be unlikely they were the problem. I put the key into the run position (climbed underneath and lined my body up with a tire to ensure certain death when it started rolling), then jumpered from the positive terminal of the starter to the solenoid wire and VRROOM. It started up and ran fine til I got home. Turned it off - no turn over with the key. Tried jumping it again just to see - VRROOM! Shut it back down and there it sits waiting for one of you to come to the rescue!

Here are some details and some recent work:
1996 XJ
4.0L I6
140,000

Recently had cracked exh manifold and rattling cat conv. Replaced with header (don't remember brand), mechanic left cat out and screwed O2 sensor #2 back into a nipple in the pipe. Flow-Tech muffler and 2.5in pipe out the back.

(before we all go enviro on me about the cat: I intend to take it back in and have a high flow cat installed. I intended to have them install it that day, but they came back with some 'forgot to order it' excuse. The day I got it back, my mileage took a crap, from 20mpg down to 12mpg. One would think with a wide open exhaust your mileage would go up... I know the back sensor was causing bad readings, and I now question whether it is functioning at all... But that shouldn't keep it from starting.

My electrical system all seems to be working just fine (aside from starting). Radio, lights, everything else is good.

Computer blink codes 12, 43, 21, 55

I did find a leak in a vacuum tube, but that wouldn't get in the way of the starter either.

Maybe it's simply the ignition switch? Is there a fuse? A relay? I'd rather not go throwing expensive parts at it again.

This thing is my toy, well maintained. Any ideas? :confused:

Check ALL cables and connections for starters...
Possibilities:
Keyed Cylinder...

Ignition Switch...

Starter loose....had this happened to me once..in the vehicle turn key...nada..
slide under the vehicle and physically see if you can move the starter with your hand...if the starter is loose what happens is when the solinoid spins it pulls away from the flywheel...therefore not start...if your in the vehicle or by your self you WILL NOT bea able to see or hear any sound or movement.
If the starter is tight and does not move then the above mentioned "could be the culprits"

Ignition switch is on top of the steering column under the dash..

Keyed Cylinder is behind the Lock Plate....

Haynes manual will give directions for both....

Hmmm...

Keyed cylinder... what thell is that? And while we're at it, what's the lock plate. Are you referring to the assembly on the column where you shove in a key and turn to make it go?

FYI - climbed under and jumped the starter today, and drove it to the shop. When I checked on it this afternoon, all the mechanics had gone home for the day so no one could tell me what the dusty black plastic cover sitting on my seat came from. Still no cat on the exhaust system. We're going to have a chat tomorrow, it was an hour after closing, and there sat my XJ - not a single door locked and my Alpine detatchable face CD/Radio right there ready to steal...

http://files.automotiveforums.com/gallery/watermark.php?file=/500/226654IJ12-1.jpg

Here it is, it now says Stillwater Electric on the doors (my company name) and has four lights across the front of the rack.

[QUOTE=IdahoJeeper]Hmmm...

Keyed cylinder... what thell is that? And while we're at it, what's the lock plate. Are you referring to the assembly on the column where you shove in a key and turn to make it go?


Yea thats what he is talking about its not to hard to replace but with the air bag on you need to make sure you put it all back together CORRECTLY and remember to disconnect the battery before you start

Hey Mints, how's it going?

Well we found it, $350 later... It was the brand new Neutral Safety Switch. AAARGH!

When I replaced it before, I evidently put the wiper arm inside in a bind. The wiper had broke off and was just floating around inside the body of the switch. When you replace one, you need to be SURE the flat fan shaped case is all the way onto the shaft on the side of the tranny. If it's out away at all, when you tighten down the smaller bolt up above, it will bind up the shaft and the switch. That's bad.

Thanks for the ideas!