Check your fuse links behind the battery. There are threads here about them.
Won't start - after 6 months of random shut off's
Hey AstroSafari folks!
My RWD '94 Astro has had some kind of electrical issues since I swapped out a dead battery 6 months ago.
It would shut off randomly or certainly if I used too many electrical features (e.g. lights on + radio + fans blowing).
I was always able to just turn off the radio/fans and restart it.
Thought I fixed it by reconnecting a stray extra wire to one of the battery terminals. I left it off because my replacement bolts didn't have a way to include it (and I was lazy).
Well recently it decided to shut off and not restart. Now the engine just turns over but nothing ever catches.
What I'm wondering - is it one underlying problem with the electrical system? Or did another problem (dead fuel pump?) just show up on top of the old one?
I'm just a shade tree mechanic. But yep, tried to get my trusted mechanic to fix the electrical thing. He refused - doesn't mess with electrical stuff.
So I've just been dealing with it.
My RWD '94 Astro has had some kind of electrical issues since I swapped out a dead battery 6 months ago.
It would shut off randomly or certainly if I used too many electrical features (e.g. lights on + radio + fans blowing).
I was always able to just turn off the radio/fans and restart it.
Thought I fixed it by reconnecting a stray extra wire to one of the battery terminals. I left it off because my replacement bolts didn't have a way to include it (and I was lazy).
Well recently it decided to shut off and not restart. Now the engine just turns over but nothing ever catches.
What I'm wondering - is it one underlying problem with the electrical system? Or did another problem (dead fuel pump?) just show up on top of the old one?
I'm just a shade tree mechanic. But yep, tried to get my trusted mechanic to fix the electrical thing. He refused - doesn't mess with electrical stuff.
So I've just been dealing with it.
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Finally having a hard fault is a very good thing, much harder to trace intermittent faults.
Yep, this is where I would be looking first as well.Check your fuse links behind the battery. There are threads here about them.
I just saw your post after answering a similar post , so I will copy paste..
" This may sound silly , but if your factory engine ground (that factory braided wire that grounds your eng block) has probably failed, being 28 years old. starter will not work in this scenario.
Factory Engine ground wires tend to fail after many years, note your engines only ground is this ground wire and sometimes a small 10 gauge at the battery post to frame.
note your engine sits on rubber motor mounts and exaust is hung underneath with straps. Engine ground is often overlooked.
Just a thought , good luck "
" This may sound silly , but if your factory engine ground (that factory braided wire that grounds your eng block) has probably failed, being 28 years old. starter will not work in this scenario.
Factory Engine ground wires tend to fail after many years, note your engines only ground is this ground wire and sometimes a small 10 gauge at the battery post to frame.
note your engine sits on rubber motor mounts and exaust is hung underneath with straps. Engine ground is often overlooked.
Just a thought , good luck "
That would affect the starter motor the most. Still good to check 
This sounds like a broken / cracked exciter stud in the alternator housing, which may have been your original problem. I had a Buick once that had charging issues and it turned out to be that. Could also be a weak / bad cell in the replacement battery compounding the problem.Hey AstroSafari folks!
My RWD '94 Astro has had some kind of electrical issues since I swapped out a dead battery 6 months ago.
It would shut off randomly or certainly if I used too many electrical features (e.g. lights on + radio + fans blowing).
I was always able to just turn off the radio/fans and restart it.
Thought I fixed it by reconnecting a stray extra wire to one of the battery terminals. I left it off because my replacement bolts didn't have a way to include it (and I was lazy).
Well recently it decided to shut off and not restart. Now the engine just turns over but nothing ever catches.
What I'm wondering - is it one underlying problem with the electrical system? Or did another problem (dead fuel pump?) just show up on top of the old one?
I'm just a shade tree mechanic. But yep, tried to get my trusted mechanic to fix the electrical thing. He refused - doesn't mess with electrical stuff.
So I've just been dealing with it.
Thanks so much for all the ideas!
We got at it last night.
Fuses-
It's a 94 - no fuse box behind the battery. All under the steering wheel. Replaced one blown unlabeled 15 amp fuse. No effect.
Factory engine ground -
There is indeed a braided cable that goes to the frame. Looks fine as far as the flashlight could shine 🤷
Alternator looked fine, but I didn't attempt to pull it out. I suspect it is more than a charging issue because the (very old) aftermarket alarm and kill switch system is not responding to the remote. Should have mentioned that before...
But it has been on the AC charger all night, will attempt to start it today.
We got at it last night.
Fuses-
It's a 94 - no fuse box behind the battery. All under the steering wheel. Replaced one blown unlabeled 15 amp fuse. No effect.
Factory engine ground -
There is indeed a braided cable that goes to the frame. Looks fine as far as the flashlight could shine 🤷
Alternator looked fine, but I didn't attempt to pull it out. I suspect it is more than a charging issue because the (very old) aftermarket alarm and kill switch system is not responding to the remote. Should have mentioned that before...
But it has been on the AC charger all night, will attempt to start it today.
Fusible links is what he was talking about, not a fuse box or blade type fuses.It's a 94 - no fuse box behind the battery.
Did you take any voltage measurements? Have your battery load tested?
My no start problem on my 1992 turned out to be the distributor, or more likely the ECM which is attached to the distributor. Took me two months to figure it out. Originally thought it was fuel pump, or a bad short.
Also had a fuseable link broke behind battery before, but when that happened there was no crank, the wire that broke completely cut power to ignition.
Also had a fuseable link broke behind battery before, but when that happened there was no crank, the wire that broke completely cut power to ignition.
Check battery voltage while cranking.
If you have no meter, old school battery test. Turn on headlights while starting engine.
Turns over fine, battery okay.
Turns over slowly and headlights look like candles, battery dying.
Provided headlights were not candles before cranking.
If the battery is okay, check the fusible links and the wiring around battery for powdered wire syndrome, wire swelling inside of casing. Check for loose or corroded connections.
Then go over the alarm system. Usually I uave found they are the source of nightmares.
If you have no meter, old school battery test. Turn on headlights while starting engine.
Turns over fine, battery okay.
Turns over slowly and headlights look like candles, battery dying.
Provided headlights were not candles before cranking.
If the battery is okay, check the fusible links and the wiring around battery for powdered wire syndrome, wire swelling inside of casing. Check for loose or corroded connections.
Then go over the alarm system. Usually I uave found they are the source of nightmares.
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