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ok i got to a certain point ... thanks mostly to Y2Kvert4me and from Bill Curlee (in a different post) ..
but after going to the dealership and attempting to explain my situation .. they wanted to replace my starter .. i told 'em i wasnt playing the replace the parts for no reason but cost to me game
so im back to where i was .. i've got the car still apart and the thing has started everytime since saturday when i tore into the car ..
so now i've got my voltmeter staying in the car .. the dash apart .. and no idea where the issue is coming from ..
i've ruled out all the grounds, the bcm, the relays, the battery, the clutch switch .. does anybody else have any other ideas?
i feel like im about to pull out my hair because everytime i go to do some more diagnostics .. the car starts.
I had a ground wire get fried by the header. I had to run an extension on one of the ground wires to the starter.
.. first place i checked .. i thought at first either my headers melted something or the heat was killing my starter ..
.. i'm not getting proper voltage ( or any for that matter ) at the relays underneth the pass. footpanel when the car decides not to start .. so it's before that.
My '02 Z06 had exactly the same problem. It turned out to be the contacts in the middle of the ignition switch. (The ones that let the PCM know that the key is fully in the switch, not the ones that make contact with the "chip".) When you insert the key the tip pushes on a pin, which pushes against a reed style contact in the very center of the ignition switch. I cleaned and bent the contact tabs about 1/64th" closer together and it works perfectly now.
My '02 Z06 had exactly the same problem. It turned out to be the contacts in the middle of the ignition switch. (The ones that let the PCM know that the key is fully in the switch, not the ones that make contact with the "chip".) When you insert the key the tip pushes on a pin, which pushes against a reed style contact in the very center of the ignition switch. I cleaned and bent the contact tabs about 1/64th" closer together and it works perfectly now.
i had thought it could have been that a while back .. i've been testing the switch on every start up thus far .. i'll try screwing with it to get it to act up.