Strange Montero Starting Problem

So I have a 2001 Montero XLS – and for some reason it will NOT start unless you press down HARD on the positive battery cable were the fusible link box is. It isn’t the battery it’s the link box. I call it a fusible link box because it is a little block box that says fusible link on it, and has fuses inside.

Basically, the positive terminal is a marine terminal corrected with a positive battery cable (not sure were this cable leads to) and a fusible link box and cable (this starts the car and feeds the car power). In order for the positive cable and fusible link to get a good enough power feed from the battery you have to press down hard on the fusible link box, and I mean to the point were the fusible link box is almost perpendicular to the battery terminal.

Does anyone have any idea how I deal with this one? In order for my car to start two people have to be there, one to hold down the box and one to start the car… I have to take it in sometime in the morning any help would be appreciated.

 

How old is your battery? I've had batteries with loose posts internally.

Assuming you've tightened all the bolts and clamps that may be your problem. Take off all the connections and see if the positive post moves back and forth. Try wiggling with vice grips or big pliers.

Ron

 

Hi Ron,

Thanks for the reply. The post seems to be strong. And I had the battery tested last night (they used clamps).

Now, could it be the battery? We tried the following:

Connected the battery as normal -- the lights are dim, and the car makes a clicking sound (relay?) when the lights are on, but the lights dont show.

When you press down on the positive battery connection (the fusible link box) the light shows and the clicking starts.

We thought the car might need a charge so we jumped it, but for it to start, again we had to press down on the fusible link box.

I am not sure how to tell if that is the problem or if it is the positive battery terminal? I think its the box. I just moved to a new town and I don't know anyone here. I talked to MITSU and they said it would take 3 days to get a fusible link box... one store said they didn't see a fusible link box for the model of Montero I have (3.5L XLS 2001).

I have no idea what to do...

 

I also suggest trying a new battery. I've had them fail internally on industrial applications and do exactly what you describe.

You may also want to try wiggling the positive cable back and forth where it enters the fuse box instead fo pressing down on the box. It may be on the "supply" side of the fuse/relay box.

 

I thought it was the battery too. And so when I took it to Autozone yesterday to get it tested (the machine said it was fine) I thought maybe fusible link box?

Well I went back to Autozone and demanded a new battery since mine was under warranty still, the guy was nice about it. I put the new one in and now it works just fine.

This battery was not even 2 years old yet!

So it was the positive battery terminal being lose internally, that is strange!

Thanks again both you guys!

 

Glad it all worked out well. I wouldn't have jumped to that conclusion but my I had the same exact problem (Kragen's battery) last year. But in my case it was more obvious as the post would move.

Happy motoring.

Ron