Hi All! Few months ago my starter relay fuse blew, so I replaced it and all was well until now. Now everytime I go to start it the fuse pops. No cranking or anything, I turn the key and all I hear is POP! Checked the relay which is fine, tore into my dash and all the wires are ok. No fraying or splits. I tried checking the starter itself and its wires but with my back it was tough enough to look under the dash let alone crawl under the truck and try to trace wires. I found the main wire running to the starter and cleaned the connections. But I'm at a loss now and probably like some of you cash is really tight now. New catalytic converter on the wifes car and new spring shackles on my truck has grun me dry. They say bad things happen in three's, well her's my third one hope it's over. Any suggestions on getting this running or is there a way to bypass it so I can start it so I don't have to tow it to a garage if i can't make the repair myself.
Thanks Alot!

 

check the starter very carefully ( when the engine is cold )
for any fraying or corroded wiring
1 of your power feed wires is being grounded out to the starter casing
( hence fuse is blowing only when you try to start )

 

The starter itself does not use a fuse. The problem is in the relay circuit.
This includes the wiring from the underhood fuse/relay box through the firewall , up the steering collum (beer speeling).
If you need to start it , turn the key to the run position , the use a jumper cable clamp accross the two larger terminals of the starter solenoid.

 

Thanks for the help, I was hoping I did not have to rip into the steering column. If the wires on the starter checks out i guess that's what I'll be doing.
So I can start it by putting one end of the jumper on the top terminal and the other on the bottom and it will fire up without frying anything else? No end of the jumper goes to the battery right, I just use use one cable from top to bottom of the relay? Could I use any type of thick gauge wire to do that or use 1 part of a jumper cable?

 

Was able to jump the solenoid and the truck started. I was even able to leave it running with the remote start and removing the key. So the solenoid and the remote start is working fine. On to the starter, ignition and the circuit itself. Thanks

 

So far everything checks out. Stumped now for 10 days.

 

Finally had to break down and take it to the garage. They could find nothing wrong with the starting or ignition circuit. They suggested it could be from all my other wiring i have like my fog lights, back up lights and off road lights. They said they could hook up a push button ignition that would bypass the starter relay circuit, but there has to be something wrong somewhere. Not sure what to do. Any suggestions?

 

are you sure that you did not tap into another circuit
that is connected to the starter relay

those added ( circuit / s ? ) could be drawing more amps than what the wiring / fuses can handle

 

Positive. And i never have anything else on when I start the truck. Everything is always powered down when I shut it off.

 

after re-reading your original post

it is clear that you have grounded out wire somewhere along the cabling
from the starter relay to the starter solenoid

you will have to remove all of the electrical tape to find the short

over time ,, engine heat and vibration break down the mo-ecular structure of the copper wire

the strands break over time and possible break through the tape and cause a short somewhere

you are looking for the cable closest to engine block,, possibly under the air conditioning pump and the power steering pump

remove the starter cable at the starter solenoid and the relay

use a multimeter and check for ohms resistance at the cable ends
if there is a short , the meter will detect it
also check for melting of electrical tape and blackish spots

 

Everything checked out fine. So I now have a push button ignition. Did find something interesting though. I lost my back up lights but I jiggled around the wiring harness connection on the right side of the motor, the small black box and they came back on. I think there may be a short somewhere in there. Either the downstream or upstream not sure where. Looking into getting a new harness.

 

keep the push button start feature

i have always prefered that type of start feature
( that is why nissan went back to that type of feature ) idiot proof

 

The push button start I like. Not to many Rangers with one. I just wish I knew what the problem was. But it's finally back on the road and i'm happy with it....mostly.