Odd ticking noises from the PDC box

So my cousin just bought a Jeep because he wanted any car. Well we put the new engine in it at 190,000 miles because the old engine blew at 390,000 miles (the old lady didn't understand that a loud knocking meant something was wrong so she blew a rod out the bottom). Everything was working great except he blew a radiator hose but that is since fixed. Now sometimes the biznatch won't start and it gets this insane clicking in the PDC box under the hood. Sounds like the relays are trying super freaking hard to kick over but aren't getting the power they need. I tested the battery, it's fine at 12.46v. So I try to start it with me jumping it to give it more power. Nope, she still clicked and would continually *rrrRRR rrrRRR rrrrRRRR* as it tried to start but wouldn't. No severe voltage drop in the battery and the ground didn't get hot so it isn't a live short to ground anywhere. We let it sit for a bit and tried a few hours (around 4 hours) later and she fired right up. Shut it down and OMG clicking without starting again. The relays are fine. I took a relay that I knew worked (horn relay) and put it in the clicking one. No effect, now the horn relay is clicking. The one that seems to be an issue is the ASD Relay aka the Auto Shutdown relay. But seeing as it made the horn relay which worked click like it couldn't get power, it can't be the relays themselves. So I pulled it out and jumpered it through a paperclip across the smaller electromagnetic pathway and the main pathway. Still wouldn't start but no clicking. Also noticed the receptacle seems really, really loose no matter what relay you put in it. Figuring this is the problem since it shut down mid-drive for my cousin (I was not there). Obviously it is the ASD but what the frick is the issue. All his fuses are intact and operable except a 20 Amp but we'll get to that later since it has nothing to do with the problem, I checked. Any thoughts?

I think you are on the right track with the lack of power to the relay

Ok but it has the correct, ample voltage in the battery for it to start so what the heck is going on? It will randomly start then randomly not start. The ASD is just getting sporadic power? If that is the case, why do the other relays for the horn and Tranny click when the ASD relay is removed? The car wasn't even started yet and even while not trying to start the car the horn worked which means it is getting power so why the frick does it click when we try to start it?! What could be causing the problem if the battery voltage is nominal and the wires are intact? I pulled apart the bottom of the PDC box to see if it was burned anywhere or kinked and nothing. They all look and feel great.

Andrew, this is probably one of those things I need to see at my place again. Or if it won't start come to you.

Do you have any time available this week to come by and look at it because even if we could start it, he has to have it smogged before he can register it to actually drive it since he only has it on NonOp right now? He's at my grandparents in Magalia.

I can look at it, but not until after a week from tomorrow. After that I am free.

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Got a pesky ASD issue on my 98. replaced relay and got nowhere. only codes are ASD related....

mine made some weird noises when I'd massage the ASD relay. I could hear/feel it actuating but it didn't work. I'm tempted to replace the PDC if it didn't mean splicing all those wires.... which i'm surely to screw up somehow...

You fellers get anywhere on Freak's PDC??

Not mine. My cousin's PDC lol and not yet. Haven't had a chance to meet up since I'm moving.

sounds like there was a fuse popped on mine that seems to have restored ASD function. Not sure how I got the erratic ASD issues from a blown fuse, but I'm done scratching my head on this one. Looking forward to getting it back on the trail

All that over a blown fuse. Who would have thought

So its fixed!!! Awesome, i know you're happy. :D

Sent via messenger pigeon - i talk, he types.

OK I EFFING FIXED IT BY PURE CHANCE...and maybe some skill :)

Cleaned out the main electrical cable that went to the distributor cap and rotor (the terminals were dirty) and wouldn't you know it? It started up right away with no clicking. Hasn't had a problem since. Only issue now is the idle is SUPER high. P/N = 1,500-2,000 RPM ; D/R (AT) = 800-1,000 (Normal cause it's under load).

I already taped the IAC hole and removed it but left it plugged in to the computer to see if it would fix it and it didn't even do anything to it. Still 2,000 RPM. Unplugged it so there would be no reference voltage. Still at 2k. Any suggestions?

Might need a new one Andrew. Sounds like it is not working

I thought the same thing but shouldn't it drop down to almost death stall if it wasn't working at all cause I unplugged it? I mean if it isn't getting a voltage shouldn't it run off a set default program code?

Not completely sure on that one, but generally when they fail they are in the full open position

I'll give it a look. Thanks. I'll let everyone know the details as soon as I do.