2nd solenoid in a row that has run on issues

[j2sax]

So these could all be unrelated.  My 82 J10 has had starter/solenoid issues since I got it.  I just fixed the starter engagement/hangup issue with a shim. 

The truck fired smoothly and INSTANTLY with none of the previous grinding and I was ECSTATIC... then I went to shut the truck off and NOTHING... yup, the solenoid stuck again. The truck kept running 

 This is the 3rd solenoid I have had on the truck... the first one was not a factory style unit and I only changed it because it was not factory style and I was having the issues with the sticky starter.  

The first replacement started hanging intermittently where it would keep the starter engaged (different issue than hanging on the flexplate that was fixed with the shim) OR the engine would not shutoff.  I knew it was the solenoid as in either case, I could bump the solenoid and it would either disengage the starter or shutoff the engine.  

Now I have a brand new, BW Select solenoid that I installed when I replaced the starter and put the shim in, and the first time I fired up it sounded better than EVER!  I was SO excited and then I turned the ignition off with no result.  Brand new Starter solenoid and I had to bump it to shut off the engine.  

The only thing I have seen as an anomaly is that there is a .06 volt at the "I" post at the solenoid.  

The Ignition Switch under the column is new.  I have thought perhaps an alternator, but then, why would the solenoid bump shut the engine off?  

Now, it only happened the first time I had the engine running, however, I do not want it to happen at a time when it is inconvenient to shut off.  

Ideas appreciated!  

Jesse 

[Ristow]

i had a weak battery that was tearing up solenoids in my cherokee. finally the exide (junk) died entirely,and the solenoid issues went away with the new battery.

[j2sax]

Hadn't thought about that... this is a pretty good battery though... a Sat Mat battery made by NorthStar. Can sit for months and fire right up.

Did your battery cause the vehicle to keep running when you shut off the ignition? I know that my bumping the solenoid will shut it off, but I cannot figure out what is keeping the ignition energized once I shut off the key. IF it were a wiring issue, I would think it would be more consistent, but it does not seem to happen all the time. It literally happened the first time I tried to shut off the truck with a brand new solenoid, but has not happened since. I guess the next time it happens I will have to be ready with a voltmeter!

I will try swapping in another battery, just to be safe. Thanks for the tip.

[Ristow]

ok...i missed that fact the first time....you have something else going on. once running,the solenoid should not be feeding the ignition at all. the I terminal is hot during cranking only. once off the starter it is an isolated terminal,which is why it is used as the exciter line for alternators in many cases.

your '82,that I terminal should be going to the MC ignition box,to the timing retard circuit to knock the timing back during cranking. the coil is fed vis the ignition switch only. i think you are wired up incorrectly.

[j2sax]

Yeah, you are probably right, however, it is likely some sort of short.  It seems if it was solid wired incorrectly, the problem would be more consistent... so far I have probably started and shut off 13 times with no issue and it was only the first time started with the new solenoid that I had to bump the solenoid.  I still need to go back through the wiring to figure out where that .06 V is coming from at the I Terminal.  At least it's usable and has not chewed up the flexplate! 

Any other ideas are appreciated as well... especially if someone thinks they would know where a specific cross might be which is requiring the solenoid bump to shut down the ignition! 

[Ristow]

does yours have the ground terminal on the rear of the solenoid? that grounds thru the n-switch on the transmission. my =n-switch fell apart internally on the cherokee,and caused some strange back feed issues once.

[j2sax]

My 82 is SUPPOSED to use the NSS, however, I purchased a Solenoid for a manual without the NSS, so that is not hooked up.

I bet that was a WICKED time diagnosing that issue! I hope i can figure this issue out to add to the archive of FSJ knowledge!

I have a feeling I am going to have to strip out the whole charging/ign side of the harness back to the firewall to figure this out... DANGIT!

Thanks for the ideas though... feel free to keep them coming as every one is good info to tuck away for later! Who knows when this NSS suggestion might solve someone else's issue.