I just put a push button on it tonight...this thing has driven me past nuts. I think it's a short some where but cant find it. Could be the NSS is out of adjustment I really don't know how to adjust the nss..I am just checking for power from it up in the relay. Electric problems always turn into a major headache for me.

 

electrical problems always get the best of us, especially when the wire disappears in a wire loom of 50 million other wires, only to reamerge with another 30 million wires.

 

I can understand being "driven past nuts".

I know if it were me I'd be following ET's step-by-step, methodical troubleshooting directions. What a great resource to have someone that can call out individual pins and explain how the system is meant to work. I wish you success.

 

how does one hook up a push to start?

I would like to do this.

 

Just run a hot wire to the positive side to the battery and the other wire to the post on the starter solenoid. The push button acts as the relay to keep from having constant power to the starter.So a wire running from the battery to the button inside the cab, then from the button to the solenoid. I just have mine wired "temporarily" until I can figure this problem out..so no fancy write up on the install. It's very simple probably take you all of 5 minutes to do.

 

Ok 2 years later I am still using the push button to start the truck...I only drive it to go camping and stuff like that. So the last couple of nights I have been going back over everything trying to figure this out and still not having any luck....

Below is what I have going on in the starter relay:
30 is always hot
87 no power ever no matter what position the key is in
85 when the key is turned on it has power and when in start position it has power
86 in run position has not power in start position there is power to it

I you understand how this relay works maybe you can make sense out of this ....I though due to 87 never having any power that would mean my problem is from the PDC to the Ing. Switch but I havent had any luck tracking the problem that direction...please please please if anyone has a solid idea ... or I am going to bow down and admit defeat and take it to the mechanic. The last thing I am going to try is to replace the key mechanism in the ignition...unless there are some good ideas coming this way.

Thank you in advance.

 

Are you testing with the relay in place??

Pin 30 should always be hot, that one is correct.
Pin 87 is output to the starter motor.....
Pin 85 is ground...... With the relay out, it should NOT have power......
Pin 86 is the feed from the ignition switch, so, that one is correct as well.

Keep in mind, this is looking at the 01 service manual, I don't know what year your truck is, but, I wouldn't think things would change THAT much over the years.... but hey, I have been wrong before.

If those results are testing the terminals in the PDC, with the relay OUT, then you have a short to power on the Black with white trace wire, from pin 85. (in which case, the relay will never operate, so, never get power to pin 87)

 

All of the info I provided was with the relay out and the ignition in different states....

So how do I solve the short to power in pin 85? is pin 85 the ground to the NSS? Pin 85 is live as soon as I turn the key on/start...the black and white trace wire splits to the ignition and to the starter correct?

Please keep in mind I bought this truck 2 years ago and the last owner spliced into several wires installing stereo, alarm and some lights. I have managed to untangle all of his mess but this one issue.

What do you know of the byPass jumper? seems that should head straight to pin 86 in the PDC?

Thanks for your help..I like the direction you are heading with this...have spent the last 6 hours trying to run this down.

1995 2500 4x4 gas 5.9

 

You can grab the 95 service manual from this thread. Wiring diagram for the starter circuit is on page 8W-21-2.

Pin 85 appears to split off at Connector 125, (this would also be a good place to look for the short......) The black/tan wire just runs off to a ground. (this is for manual transmissions.) The Black/White wire runs off to the neutral safety switch, and then ground. With the relay out, that wire should NEVER have power.

Gonna have to trace that wire its full length, to find the short. Other alternative would be to just replace it with a new wire, from the pin in the PDC to pin 2 on connector 169 (at the NSS).

 

Excellent...thank you for the link to the manual and your help, I appreciate it. I wont be able to work on it until tomorrow..but will update this thread with results. Happy 4th !