Hi all, I don't know why, but I bought another Disco 2. After installing a new XYZ switch everything was smooth sailing, until the other day when I went to start the car and all I heard was a couple of clicks. I thought, no biggie, I needed a new battery anyway. New battery in, click. New alternator in, click with some turnover sounds. I believe the new battery had enough juice to push through whatever short I'm experiencing, then I started smelling smoke, looked down to the window switch panel, and smoke coming through there. Unplugged the battery and upon inspection on the underside the cable assembly coming out of the transfer case drum (not sure of the name) was hot and had smoke coming off it. (See picture) I figured I would check here and see if anyone has ever had this issue before or have any tips on where to start. Does anyone know what this harness is?



wire harness wrapped in sleeve was smoking


Short version, car has a short somewhere and I'm looking to see if anyone has had this issue before. Cars are pain.

 

Is that the wire going from relay to starter or the power wire from battery?

I'd bench test starter maybe some taps with a hammer to see if you can get it unstuck.

Looks like you're getting power to the starter but relay jammed?

Just to be sure also try to turn engine by hand (learned that the hard way on my dad's boat haha. Engine was seized)

If tapping works then many choose to replace starter anyway.

 

Thanks for the quick reply!
Is that the wire going from relay to starter or the power wire from battery?
- This is the wire harness is going from the transfer case then up to the center console. No idea what it is
I'd bench test starter maybe some taps with a hammer to see if you can get it unstuck.
- Tried some taps with the hammer, no such luck.
Looks like you're getting power to the starter but relay jammed?
- Tried switching some relays around and nothing.
Just to be sure also try to turn engine by hand (learned that the hard way on my dad's boat haha. Engine was seized)
- The engine should turn over as I was just driving it the day before, and when I had fresh battery I heard it turning over slowly. (Yikes about the boat haha)

 

Photo looks like the cable from the hand emergency brake lever to the drum brake. It is not an electrical wire. The cover is heat shielding because it is close to the exhaust pipe.

Maybe the heat shield is touching a hot wire inside the window switch area and causing a short. Perhaps try digging in there to search for more burning or wiring issues. There may be blown fuses at this point too.

Years ago a friend loaned me her car if I picked it up from the shop. The battery had not been secured properly and it contacted the hood, welded on, and burned up lots of wiring for a total loss (OUCH). Glad yours didn't go that route.

 

Ground straps missing or disconnected and then the hand brake cable acts as ground strap? The amps fried the hand brake cable?

 

As above; if the battery minus lost connection to the starter, the parking brake cable acts as a poor conductor overheating as is steel instead of copper. Check grounding from battery minus to engine block/starter.

 

And back of LH head to body (maybe that’s only on my P38?).

 

My '04 D2 has two ground straps as well.

 

You are completely right, my e-brake is completely gone. The ground on front of the engine was loose. Thank you kindly. Now to fix the E-Brake