Sorry to miss your post , I am trying to keep up with your progress so that every day is a day of progress toward completion . It literally gets confusing when we read different color codes on the dura spark ignition module . I am hoping to see the mailman deliver my original reprint of the 1980 AMC jeep shop manual soonest as I need to verify if that module on your jeep is correct . Although that would not cause the starter to burn out as they have been , I want to be certain that the module absolutely matches the system your jeep requires. I have never seen these modules drastically different , not to say you can use any one on any engine , computer controlled engines may have a difference , but lets not throw that in the works as that is not the case here. I just insist on being able to say what is right and what isn't since we are not willing to just burn up more starters and damage wiring harness through trial and error.
Agreed , it should not be this tough , but it seems we have a unique problem , a modification may be at fault. I say this because there is a dash mounted ign. switch when there is supposed to be a column mounted switch . Not certain that plays a part , I don't think there is any different resistance value to contend with there, but we cannot leave no stone unturned . I've never seen starters burn up like this . Only once did I see a defective solenoid crank a starter when the B+ connection made. All connections were verified too. A new solenoid to replace the "new" solenoid fixed it. While this is not happening to your jeep , something is causing starters to overheat.
If no voltage is read with ign. on at the cable from solenoid stud to starter , key not in crank and ign. on , then Lets be sure the rest of the jeeps wiring harness is correct to rule out incorrect current route. The moment I get that manual , since I cannot trust anything else I get my hands on , I will study from column to coil to starter what is supposed to be versus what we got .
i intend to copy and send you personally all pages concerning your jeep's under hood and dash wiring to help,you get it right . Every electronic ign. I see , seems to be similar , but I want the wiring diagram a 1980 CJ 304 CID is supposed to have . We are correcting what someone did prior to,your purchase of your jeep are are faced with putting it back together. I could say why not just get a harness from Painless wiring , but I would not tell someone to spend that kind of money when it may not be necessary . I'm sure that with parts from the other jeep , there is no reason why a proper harness cannot be made. Even if wires must be individually put together as you have been doing , the end goal is to have a complete and correct harness. Only the book will tell us that . That being done , we can isolate errors more efficiently , if the problem does not magically fix itself. Stranger things do happen. I rewired a friends '92 olds delta 88 under the hood using spare harness for a donor car ( a '92) and we finally got it started after months of try try again , research and pulling our hair out . It's got to be right , or it won't go. We have one thing on our side , you don't have to deal with a PCM , just a solid state ignition system.
Your post shows a diagram that is basically similar , but I only got that car started by following the book . WE CHECKED EVERYTHING that was of relevance and concern. No wonder no station or diagnostic wanted the job . With the book , we must get this beat. If asked why I am so adamant regarding this jeep , it is likely I may have to deal with this someday if I land a CJ5 of my own. What greater way to get a start than here ? If I found one not running for a good price , I will be in the same place as you . That is why the determination. This is not my first no start , I have learned that not all are basic , but unique. We will prevail . Greg92jeepxj
