Over the years I have had a little problem with my starter just clicking when I go to start it. A battery change one time seemed to fix it, a starter change one time seemed to fix it. So, here is my problem. It is back again with a vengeance...

This is a 92 3.1L doing a rolling restoration. It now has a new clutch switch, a new start enable relay, a new battery, new battery cables, starter is new with 10 months and less than 8K miles, the ignition switch on the lower steering column is nearly new with 2 1/2 years and 25,000 miles. Engine is rebuilt with less than 8K miles. I have added padding to the clutch switch to make sure the switch is all the way depress when I push the clutch in. When it does start it turns over like everything is brand new, starter is fast and solid and it starts without hesitation. It takes anywhere from one or two trys (clicks) to as many as 8 to 10 before it runs the starter.

Anybody had a similar problem or have any ideas? Since it clicks the starter solenoid, I am guessing the computer is sending the start enable command to the relay. That only leaves either a new part gone bad or some other wiring as near as I can tell.

 

I would start hunting for a corroded wire or bad ground since you have replaced so many parts and it doesn't seem to fix it. Time for a wiring diagram and lots of anger/frustration.

 

X2

The main battery cables can look okay on the outside, but if you cut through the insulation, they could be turning to green powder on the inside. For as little as they cost, it's probably not a bad idea to just replace them anyway.

 

Battery cables can be ruined inside and look fine.

 

Mine has done that 2 different times in the past, each time it was the starter solenoid. The cables and battery were all fine, but you would have to click it 3 or 4 times (sometimes more) before it would finally start rolling over. That audible click is the solenoid jumping the starter into gear, but because the electrical contacts are burned or corroded, it doesn't make electrical contact, so the starter motor does not spin. I didn't even bother to change the starter, just pulled it out, bought a new solenoid, swapped the solenoid, and put the starter right back in.