As seen in the picture I posted above, the relays in the engine bay are not supposed to be in a 1996 XJ. When I search the number in the top of the relays, it comes up as a TJ, from the late 1990’s, and newer model Jeeps. Did foreign jeeps get different fuse boxes/relays? Mine is a RHD from Japan. Or is it possible a previous owner swapped out the box?

 

It’s hard telling but probably factory. According to the webpage below, it was used on the 97-01 XJ. And 1996 was a transitional year. Some of the old, some of the new, some specific to 96 only. Even here in the USA, I went into NAPA asking for a cap and rotor for my 96 4.0, and he said there were 4 possible distributors for that year and I’d have to bring in more info. In non USA markets it could be even more unpredictable what was used.

https://www.crownautomotive.net/Micr...y/4608650.html

 

That explains why the last distributor I bought gave me a check engine light.
I had bought a new one because I thought the old one was worn out and leaking oil up through the rotor shaft or something. When I realized the old dizzy wasn't leaking, I put it back in and the CEL went away. I think it had something to do with the timing and where the cap contact points are in relation to the rotor spinning around. Apparently its just a couple degrees off or something. Jeep ran fine it seemed like, but it didn't like the new dizzy orientation I guess.
Sounds like I made a great decision getting a 96 if they have different parts installed, depending on if its a new part, old part, or specific to 96....

But hopefully its just your relay that's gone bad.

 

consider to inspect the underside of the PDC, or at least have a very strong look at the pins

If that is all skanked, relays will be unreliable

RHD '96 PDC relay layout can be anything, BUT it does say o the underside of the lid

afaic the A/C/ASD and fuel pump relay are all the same sort, maybe some others...so you can easy swap A/C relay. Mark them first

Its fairly easy to remove a rely, make a harness and test it out

 

So, as I was checking the relays, the only two that were solid were the ASD, and Fuel pump relay. When I tried removing the Starter, auxiliary fan etc….the black case came out leaving the guts of the relay exposed and still plugged in the box….figure, that can’t be good…got all 6 on order at Napa, will post a pic in a couple of days when I get back home!

 

Sounds like corrosion in the relay box. Likely a lot of the reason for the iffy performance to begin with. I would clean it up when installing new relays.

I’m sure other folks here got better ways, but here’s what works for me. I use a little PB Blaster in the terminals, and push the relay in and out maybe 10 times to clean the connection. Then a coat of silicone grease on all new relay terminals to help prevent future corrosion. This is what I had to do a year after installing a new headlight harness.

It would also be a good idea to remove the relay box and check for corrosion in other places. I haven’t done it on a Jeep, just other vehicles.

I’ve tried Deoxit, both on vehicles and household appliances, and for some reason it didn’t do much of anything to freshen terminals. At $20 a can I was disappointed.

 

 

here’s what 2 of the relays looked like when I pulled, or tried to pull them. Replaced all 6 of these, and cleans the box/connectors!

 

I'd call that a product/manufacturing defect.
Unless they're the original relays put in when the Jeep was built and are really old... But I've still never heard of that happening haha.

 

did that fix everything ?

the relays like that means someone has been un there before, almost certainly to deal with....faulty relays !

pushing down the contact arm will activate the relay, place lid back on

if it needs to stay on, a thin twig works

handy to know if caught outback

 

I believe those were the original relays, but can’t be 100% certain. I replaced all 6 of those, and it fired up with no hesitation. Warmed it up for about 15 minutes and then went for a drive with my wife. No issues, no hesitation. So far, it appears to be running great. Hopefully it continues!