• Hi Guest!
    If you appreciate British Car Forum and our 25 years of supporting British car enthusiasts with technical and anicdotal information, collected from our thousands of great members, please support us with a low-cost subscription. You can become a supporting member for less than the dues of most car clubs.

    There are some perks with a member upgrade!
    **Upgrade Now**
    (PS: Subscribers don't see this gawd-aweful banner
Tips
Tips

BJ8 stalling out to due electrical issues

pkmh

Jedi Warrior
Country flag
Offline
My 1967 BJ8 Austin Healey is stalling out, but this time it is definitely electrically related. Since I have a little better understanding of causes and effects, I am presenting it here with hopes of better insight and solutions.

History of events:

Ever since I had a new battery installed a couple of months ago, I have been driving the Healey for approximately a total of 10 to 15 hours so far. Never experienced any problems whatsoever.

But, a few nights ago, I was driving until night came and so I drove with my headlights on. Everything was fine until there was a brief moment of no power and no lights but suddenly everything resumed as if nothing happened. Then, a few moments later, it did it again but the car did not revert back to having any power. The car completely died and would not crank over. The cause seemed simple enough which was the result of the positive cable having separated for the battery terminal. I was able to reconnect and luckily jump start and make it back home but ultimately lost all candlepower to my headlights and stalled out in the driveway.

The next morning, I charged up the battery, which by the way, is only a few months old. Then I purchased a voltmeter and tested a few things:

A. Before attempting to start the car up, the recharged battery was registering 12.0 volts.
B. Then during the idling phase the battery still registered 12 volts, and after putting the headlights on for a moment and then turning the lights off, the battery voltage dropped to about 11.93 volts.
C. Again during idle, I tested the generator. I was getting a no reading of voltage. But after “spiking” the positive lead from the generator, and at a revving idle, it was putting out .5 volts. Never went higher than that (never did before, for that matter).
D. Then I tested to see if there were any breaks in the wires to the generator and to the battery (ohms). None indicated.
E. No tests were done as of yet to the voltage regulator. Because there are several wires leading from it, I am not familiar with what or how to proceed.
F. All fuses (2 total), were okay or nothing blown.
G. Later, I let the engine idle with headlights and high beams on as well as the directional signals working for about a half hour. Car remained idling and no dimming of the headlights. I figured everything was working as it was before.


I went out today thinking everything was back to the way it was. Then I broke down again after the car started bucking in first and second gear and then would not restart after the engine was off. This time, it was NOT the result of a severed battery cable. AAA came by and boosted the car and the battery read 8 volts. He was kind enough to checked the generator during idle for me and noted how it was not putting out a charge. But he was confused as to why the car did not quit after idling for about 10-15 minutes. And then I was able to get it back home (25 minutes later) without further incident.

Other possible points of concern:
1. The tachometer, currently not working, has not yet been rewired due to the positive to negative conversion of the battery (before I purchased it).
2. The cutoff switch seems to have only one wire connected to it (a predominately white wire or white with a dark stripe). I understand there are two wires connected to it and if so, what is the color code of the second wire?
3. My ignition light has always remained dimly lit from day one. Never goes out during idle or acceleration.

In terms of what does work electrically, my headlights work including the high beams, all signals work (although flashes to quickly--flasher problem?), brake lights work, wipers work, horn works. Don’t know about the heater blower, yet.

Again, tach and cutoff switch do not work or as of yet. Interior panel lights, if I have any, do not work.

Is it a clear cut issue of the generator malfunctioning? Maybe the Voltage Regulator as well? Maybe when the cable was separating from the battery terminal that night could it have caused damage to the generator, etc.?

I remember one fellow mentioning how the tach and/or the cutoff switch could be the underlying cause of stalling out. I am bringing this up for that reason, too.

Has anyone else went through this as I have and what further steps should one take to try to fix this? As a thought, I was thinking of having my generator brought in for further testing. Should this be the very first step?

Thanks so much for any input offered.

Paul
1967 BJ8
 
I prefer not to get involved in electrical discussions but I will make 1 comment. A generator puts out next to nothing at idle. You need to run the engine at speed (I'll let someone else say what speed) to check the generator output and voltage regulator function. It sounds like the charging system isn't working, probably the generator or voltage regulator. Hopefully, someone will chime in with a procedure to check them out. I've done it and its not difficult, just to lazy to look it up.

Marv
 
pkmh said:
2. The cutoff switch seems to have only one wire connected to it (a predominately white wire or white with a dark stripe). I understand there are two wires connected to it and if so, what is the color code of the second wire?
Hi Paul,
With an intermittent total failure, the cut-off switch sounds like a good place to start. There should be three wires attached to it.
1) Big cable from battery (in your case, the negative terminal).
2) Another big cable that goes to the frame.
3) White wire with black tracer.

What I would do is put both cables on the same post. Disconnect the white/black wire and wrap it with electrical tape so it doesn't contact anything. This wire is for disabling the distributor (anti theft). Doing that should completely bypass the switch, see if that solves your problem.

Off the top of my head, I think the engine needs to be turning around 1800 RPMs for the generator to be fully functional.
 
One other thought, are the battery cables fitting the terminals of the battery correctly? I think some batteries have different size terminals so if you changed polarity one might be a loose fit.
 
Hi Paul, if you have a shop manual the section on testing the generator (dynamo) is very explicit and easy to check out. Even at idle the generator should be putting out approx. 13.4 VDC at the terminal. Again consult the shop manual, it involves removing all cables from the generator and doing a simple field test.

Some other simple things to check out; tighten all the terminals at the fuse block, they get corroded and even may seem tight but really aren't. Tighten the leads at the voltage regulator and the brown wire from the regulator down to the starter relay on both ends.

I really think your problem is an intermittent connection somewhere.
 
The very first step is the battery reguardless of how old it is. A healthy 12v battery produces 12.6 volts at rest, fully charged, not 12.0 volts , which indicates to me that you have a cell that is bad. Take it back to where you bought it and have them test the voltage and put a load on it. Nothing will ruin a generator like a battery with a bad cell, it causes the generator to overwork at high amperage. I sell at least a hundred batteries a year ( rv dealership) , and may see one or two that are just bad from new , it does happen. Also, provided you don't have a connection problem or such, your generator is "caput" , have it professionally rebuilt and it will last 30 yrs. Rebuilding it without addressing the battery first could cause its failure in a few months. good luck.
 
before attempting to start the car up, the recharged battery was registering 12.0 volts.
B. Then during the idling phase the battery still registered 12 volts, and after putting the headlights on for a moment and then turning the lights off, the battery voltage dropped to about 11.93 volts.
C. Again during idle, I tested the generator. I was getting a no reading of voltage. But after “spiking” the positive lead from the generator, and at a revving idle, it was putting out .5 volts. Never went higher than that (never did before, for that matter).
D. Then I tested to see if there were any breaks in the wires to the generator and to the battery (ohms). None indicated.
E. No tests were done as of yet to the voltage regulator. Because there are several wires leading from it, I am not familiar with what or how to proceed.
F. All fuses (2 total), were okay or nothing blown.
G. L

Doesn't this just smell of a bad generator and now the battery too------Keoke-- :frown:
 
Sounds like a good time for a alternator conversion. I would take a hard look at cut off switch and battery post leeds also... I hope that the tach power is not still hooked up. If it has not be converted yet make sure its is not connected to power. Generators.. while even working do not put out alot of amps.But the sudden cut off of car does lean toward battery post connections or cut off switch. Iam leaning toward cut off switch and since your ignition light does not cut off you are not charging either. Wheelguy
 
Hey Paul,
I don't do electrical very well but here's my two cents worth. REALLY check out that kill switch in the trunk and the connections. Follow Greg's suggestions on how to double check it. All I know is I had a 67 BJ8 back in 1978, all ready to take a couple of nice laps at Mid America Raceway track in St.Louis with the local Healey club, and no power, electric anything. We about tore the car apart trying to find the problem and turned out to be the infamous white wire was grounding out and killing the car. Driving over the grass to get to where we all parked caused it to come loose and after I parked, it touched ground and that was it for me ! Never did get to take those laps !!!!
Good luck,
Mike
 
If the only wire connected to the kill switch is the white with black stripe, and not the battery cables, that's not your problem. If the battery cable and cable to ground are connected to it, it may be your problem.

I agree with Brinkerhoff that a fully charged battery should read 12.6 volts or above. At only 12.0 volts after a night on a charger, the battery isn't helping. I just had to replace a new one on my BJ9 that was bad and less than a year old and had the same symptoms.
 
A battery with a bad cell and a non functioning generator will not hold a load and quickly lose voltage ( the 8.0v that the tow driver discovered)causing the ignition system to fail and definately not have enough left to turn the starter motor. A car will run a long time with a fully charged good battery and no generator. You could still have other problems of course ,but you'll experience more battery related problems running one of these cars than the shut off switch in my opinion.
 
Thanks for all the above advice. I have to absorb all that is said and it would be to my benefit to hook up with others and have a session or make visual comparisons.

Since yesterday after I broke down, the car has remained in the garage and unstarted since. For the heck of it, I checked the presentvoltage of the battery and got a reading of 11.93 volts. Hooking it up to a charger and voltage started reading 12.6 volts. After disconnecting the charger, the voltage went back to 11.93. Realize the charge was only for a brief period (5 to 10 minutes).

When I mentioned how I charged the battery up the other day, it was for about 4 hours only. In order for me to really know just how high the voltage is holding in the battery, need I leave to charger on for say, overnight?? The charger I am using is a 6 amp unit, 12 or 6 volt option...a very simple unit. With respect to the battery possibly having a bad cell, I figure I could bring it back and have it tested. By the way, I did have new terminals installed to the new battery so everything is tight (the cable is what seperated from the terminal, not the terminal from the post). That was a combination of the battery rattling around and my error in not tightening enough or clamping the battery from moving.

I also tried to pay closer attention to the cutoff switch and its setup. I do see a negative ground cable connected to the base(?) of the cutoff switch and that one white wire with a black tracer. That's it. I do not see a second "cable" unless it is concealed from view or connected elsewhere or nearby and away from the cutoff switch. I will try to hook up with someone having a complete connection and make the comparison that way. Having visuals would be a great help for me since I have nothing to compare my setup with.

That's all I can say for now but as I go forward, I will share my results.

Thanks for all the help. Any other advice, please keep it coming!

Paul
 
Well obviously there are two cables connected to your battery[ otherwise the car would not run at all ] one cable goes via long route to the starter solenoid in the engine compartment the other goes to ground via the cars chasis some where other than at the cut off switch , Find that cable it is in the boot. Further one terminal of the cut off switch as you have defined it is empty. when you find the other cable from the battery mention earlier, connect it to the switch. Turn switch off car will not turn over. Turn switch on car will turn over and run.
 
For Paul only, no peeking. Not even you Keoke!
<div class="ubbcode-block"><div class="ubbcode-header">Click to reveal.. <input type="button" class="form-button" value="Show me!" onclick="toggle_spoiler(this, 'Yikes, my eyes!', 'Show me!')" />]<div style="display: none;">
coilwiretobatteryswitchsm.jpg
[/QUOTE]</div>
 
pkmh said:
need I leave to charger on for say, overnight?? The charger I am using is a 6 amp unit, 12 or 6 volt option...a very simple unit.
If your charger shuts off automatically, yeah charge it overnight. Take the battery out of the car to be safe.

pkmh said:
With respect to the battery possibly having a bad cell, I figure I could bring it back and have it tested.
I'd hold off on that for the moment.

pkmh said:
I also tried to pay closer attention to the cutoff switch and its setup. <span style="font-weight: bold"> I do see a negative ground cable connected to the base</span>(?) of the cutoff switch and that one white wire with a black tracer. That's it. I do not see a second "cable" unless it is concealed from view or connected elsewhere or nearby and away from the cutoff switch.
I think it would help us if you posted a picture of that. My visual makes me think the connection is dodgy. If the ground from the battery is connected to the frame via the bolt that holds the cut-off switch, that may be the problem. If the paint wasn't stripped off the frame you'll have a poor ground for the whole car.
 
Greg,

I will attempt to post a picture of my cutoff switch here soon.

Tomorrow, I plan to meet up with another Healey owner to see how his cutoff switch setup is and compare it with mine. His is apparently all original and working.

In the meantime, I do have the charger on the battery and I also felt it was a good idea to keep the charger outside the car. I will leave it connected overnight and then test the voltage in the morning. Hopefully, it will read at or more than 12.6 volts.

I will also perform the test with the battery cables, once I see what's going on. Thanks and I will be back with results.

Paul
 
I recently bought a 500-amp load tester (similar to this, but I got mine from Amazon: https://www.harborfreight.com/500-amp-carbon-pile-load-tester-91129.html).

The battery in my BJ8 wasn't giving me any problems, but it was almost 7 years old and I was getting prep'd for a long road trip, so I bought the load tester and tested it. The tester indicated the battery was borderline at best, so I sprung for a new one. I didn't expect it, but the engine spun over better on starting with the new battery.

If you have several vehicles this is a worthwhile investment (esp. at this price). A battery will seem OK, until it isn't. The voltage reading while not under load means next-to-nothing.
 
If a fully charged 12v battery does not indicate at least 12.6 volts at rest , the test is conclusive , the battery has failed . Its not worth load testing as it definately won't hold a load at all as it has a weak or dead cell. Your first test of the battery would be of its voltage at full charge. Then if a 200A load is applied for 5 seconds , a healthy battery will drop no further than 9v & respond quickly to 12.6 volts. Though the ignition light on Paul's car staying on does indicate generator failure also , the battery needs to be right . His battery may just need to be fully charged to be fine, hopefully. At 7 yrs. Bob's battery could still have shown 12.6 v but with most of the surface area of the plates eroded , not withstood much of a load as he found out by replacing it. I've got 5 yrs. out of one of the original type tar top batteries in my Healey but now its just starting to give indication that its at the end of its life.
 
Back
Top