JBeachstang11

I have a 1990 GT that I have been working on for a couple years. Car is an auto to 5spd swap by Previous owner.

Car had been cranking fine until recently. Will start fine when jumping off the batt terminal and 12v post on solenoid just not on key. Car has brand new Ignition switch although I just noticed the black housing all the wires are in that clips into the ign switch is cracked. Need to swap that but not sure if that is related here.

Problem at the moment is low voltage to the small start wire on the solenoid that should have 12v signal. When I try to crank the voltage at that blue/red wire is only 1.2v~. Other issue is the pink/white wire off the ignition switch along with the larger yellow wires are getting very hot when attempting to start. I checked continuity from pink/white wire at the ign switch to the solenoid (red/blue) wire and that checks out.

Only thing I can think of is if any of these wires are grounding/shorting out under the dash?

Thanks!

mjr46

shorting is not the issue, when you have voltage drop, it is a connection issue.......the wires that are getting hot indicate excessive current draw and most likely it's high resistance in a connection right in the area where the wires you see that are getting hot

JBeachstang11

Ok so sounds like I need to check possibly the NSS/CSS connections and any other connections down there I am not familiar with.

mjr46

look for melted or wiring that has gotten hot

JBeachstang11

Thanks for the help I will check the connections there. I know the wires I mentioned are getting very hot. I wouldn't mind bypassing the CSS altogether if that is the problem.

JBeachstang11

I'll try to upload a picture but the wiring harness that plugs into the actual switch is a problem. The purple/white wire had fallen out of the harness connector and the plastic body of the connector has melted slightly in one area and is cracked in another. Seems most prudent would be to splice in a new connector/harness there. May attempt to plug the individual wires into the switch and see if my voltage/heat problem subsides.

JBeachstang11

Pink wire gets very hot

JBeachstang11

So I decided to probe the white/pink start wire and I only get 9.5v right at the ignition switch, the 1.2 at the solenoid wire.

The ignition switch is new. Also yellow wires are supplying 11.93v both.

When I pull the pink wire off and test that spot on the ign switch I get full 12v, but with the pink wire on I only get 9.5v.

mjr46

you need to cut that harness connector off and put a new one in place and solder and shrink wrap the splice.......most likely and it's hard to see but it looks like there might be a tad of corrosion that has wicked its way from the pin connector up into the crimp area of some of the wires with the yellow tracers