No Start, No lights ?

[Astro777]

Hi,
I and a friend are working on trying to figure out the problem with his 1994 Astro. It had an intermitent starting problem that has now become permanent no start problem.

The engine starter is doing it's job perfectly. There to our knowledge is no corrosion on the battery cables ( couldn't see down by the starter though). We cleaned the terminals for the battery cables and battery. We replaced what looked like a melted relay under the hood of the vehicle. That part is all good now. We checked all the fuses and they are good. There are two or three breakers installed in the fuse box that we have no way of knowing if they are good or bad. We left those in place I believe.

What's happening is the fuel pump is not priming or turning on. The headlights won't come on, and the dome lights won't come on.

We think it may be a fusible link that we can't find. Do you guys have a good sugestion as to what may be the problem?

Thank you for your help... his family/4 children REALLY need the use of their van.

[old_master]

The underhood power distribution box has a connector on the underside that tends to loosen and/or corrode. If memory serves correct, there is a fusible link under the box also.

[Astro777]

Thanks! We will give that a look and check for loose or corroded connections there... if that doesn't work will try to change out the fusible link. Get back to you with the results tomorrow

[brcidd]

My '94 Astro did the same- there are four fuseable links that plug into the firewall right behind the battery- they tend to corrode at the connection and disconnect-- the Horn is on the same link as the fuel pump-- so does your horn work? I had two of those link connections go bad- so I rewired all four into one common terminal- have not had a problem since-- you can also test, or drive the vehicle by applying 12v battery hot to the fuel pump primer connection at the wiring harness (red wire plug) just above the HVAC module underhood front right side of engine compartment- I was able to drive may van home that way- then found the real problem later- and fixed it.......

[Astro777]

We checked the power distribution block behind the battery at the firewall. The 4 wire connector was melted on two of the female terminals. The two fartherest to the driver side I believe. Can a new connector be purchased and where would we buy it if so? Also those 4 wires have what look like 4 fuseable links on each wire. Do you suppose one or more of those links burned out? We believe we repaired the problem that caused the connector to burn - a bad relay and a bad ignition switch from a while back. Will a new connector come with 4 new fuseable links attached?

thank you both

[brcidd]

I simply cut the melted connector off and then fashioned a ring terminal on the existing link and mounted it to the accessory post just to the right of that connector- The fuseable link will be fine if you simply cut off the bad area- the link in this case does not burn out- it simply archs across the poor contacts in the terminal block- you will never have the problem again if you mount all four fuseable links to that accessory post- This was a bad design and the looseness of the connector causes arching- the arching causes heat and the heat melts the connection even worse- now to fix it you would need both ends of the connector- and then step right back into the poor design again-- If you remount the links like I advised you will never have that problem again- Mine have been remounted for nearly 8 yrs- didn't want to spend the money for both ends of the connector, and didn't want to have it happen again. I have seen personally 3 Astros do this- yours is the fourth....Good Luck..

[Astro777]

Here is a couple photos of the connector and wires in question. I'm not my friend, but I think he will be against using any rig that is not factory original, even if it does short out all the time. Will GM sell a new connector? If it shorts out it will just be on him that he didn't want to make it better LOL.

I couldn't upload the photos, guess I don't have that option as a new forum user?

[brcidd]

Actually, it is not shorting- it is arching due to a poor connection (loose) there is a difference- the connection cannot carry the load needed and it gets hot and melts the plastic connector- the terminals are burnt and need replaced- so good luck- If you look at the wiring diagram, you'd ask- why does it plug in there? why not simply bypass the bad connection- that was there for the assembly plant ease of installation only......anytime you clamp a connection together is better than a slip fit connection-- just my engineering opinion......

[Astro777]

Thank you, you all have been very helpful in diagnosing the problem. I leave it now in my friend's hands to choose how he wants to proceed with repairing the problem. I did forward all your ideas to him.

Thanks again

[Deadcarny]

want to thank AF.com!

This old post saved my ass tonight. My Astro ('92/240k miles) died while over 50 miles from home with my girl and 4 of the kids with us. I figured it was a plug somewhere since I had lost so many accessories and the fuses were all good.

here is what was not working:
H-lights
T-lights
Courtesy lights
Horn
Dash Lights
cig lighter
Radio (but lights on radio worked?)
mirrors

I am sure there was more. Windows worked, signals worked, Fan (heat/ac) worked, starter cranked....just no start!

So I called my dad and had him search the net with no luck....till I told him to log in here to AF.Com. He found this thread and read it to me. I went under the hood and found the plug and wiggled the shit out of it. Looked in the van and the damn courtesy lights were on! turn the key and there I was, running again!

Thanks AF.com!