Testing complete need input please..

[ballysdad]

Ok hard start problem 25% of time.
Turn key and get only sound of starter solenoid trying to do something nothing happens.
Repeatedly turning key yields same sound until it finally catches and starts no problem.
1. Can be hot or cold does not matter
2.Battery replaced charged and tested with voltmeter and charging system checked with Sears equipment. Battery test good 12.6v, 700 cranking amps,35 millivolts draw when car is off..Altenantor tested diodes working, Full amperage output and voltage while at idle 14.2v
3. removed starter bench tested ok everytime with 12v across terminals solenoid catches armature spins out and spins freely. Took starter to PepBoys put on their tester tested perfect 3 times.
4. Without starter installed full battery voltage at starter on Main cable. 11v-11.2v when key is turned on ignition wire.
5. Before all this ignition switch was replaced.
So I wired a test lead from the starter solenoid to a voltmeter so when I turned the key with the starter in I could see what voltage I was getting to the ignition side of solenoid.
When the car starts I get between 10.5v and 11.2 volts..Voltage may be skewed a little by the setup for testing but starts no problem.
When the car doesn't start the voltmeter shows 7v at the soleniod. After turning key 5 or 6 more times shows 10.5-11.2v and starts.
Does anyone think I could have a dead spot in the starter solenoid drawing excessive voltage until it finally catches? Would a dead spot show up on any other test I am missing?
Any input would be appreciated.
Thanks

[flash968]

sounds like a bad main ground

[ballysdad]

I will check my grounds again to make sure.. I think I am going to also cround the starter body on its own as well to see if that clears it up.

[911Rich]

Starter drive may actually be getting stuck on ring gear, check ring gear tooth condition while you're at it.

Deadspots in starter are very common, worn brushes or slipring area will do this.
Starter solenoids go bad all the time and solenoid "short" cable into body corrodes causing bad contact.

[idontknow]

the 7v when starter isn't turning leads me to think it's a short and not a arc point in the solenoid. My vote would be slipring.

[ballysdad]

Will the solenoid intermittent failure not show up on a test done with a machine at the shop? It bench tests fine that's why I took it somewhere and I watched it test good 3 times. I always thought it was the solenoid based on the symtoms just wasn't sure.

[idontknow]

That's the trouble with intermittent problems. It'll work every time someones around to watch, but as soon as you're alone with it the problem rears it's ugly head.

[bazar01]

If it bench tested good, you have a problem with the 12V supply from the ignition switch to the solenoid terminal. Reinstall starter and wire a 12V source straight from the battery to the solenoid and see if it works.

[kmakovac]

the starter have a selenoid switch that push the starter gear on the ring,i have the same problem with my 924
i test the starter and it works in the garage but when you put it in the car he turn the engine every 10-20 times you try!
the selenoid have no enought power to push the ring out and rest in this position untill the engine start
my mecanic resolve this with a small spot point on the selenoid that comes in contact with the lever for the gear(a good electrocar machanic know this),whit this spot the selenoid is closer to the lever and have the power to push the gear
maybe is simple to buy a new selenoid switch