Hi everyone, I have a '92 929 that won't crank some times. You just hear a single click. After a few tries it cranks and starts running. Other times starts right up.
Used to happen only in the summer, but now it happens all year round.
Also, the engine can be cold or hot when this
happens. So far I replaced the ignition switch, and starter. Battery is fully charged and load tested. I also added a ground cable straight from the starter to the chassis, and from the battery negative to the chassis. I tested the positive cable at the starter and barely any voltage drop when cranking. I also checked the positive cable at the alternator.
Any ideas? Car has 185k miles and runs really well. This is really the only problem with it. I've done all the maintenance on it for the last 13 years. I am the second owner.
Thank you for any help you can give me.

 

I would think the starter solenoid is on its way out.

 

Thank you for the reply. I thought the same so replaced the starter. Same thing. I exchanged the new one for another new one and same thing. I forgot to mention I also replaced the starter relay.
I just don't know what else to try.

 

nelaco:

I am just tossing around some ideas:

Is it an automatic? If so the neutral safety switch or transmission range sensor could be at fault. Try wiggling on the shift lever to see if makes a difference.
If it is a manual you may look for a clutch safety switch. I am not very confident that this leads to the cause of the problem. If it were the safety switches you would not hear the click.
Can you get someone to turn the key while you hit the solenoid with something?

How bad are the teeth on the flywheel? Do you have grease on the cog? If it were mechanical you should get some additional noises.

 

Clean and tighten battery cables.

 

Thank you for your replies. I just noticed them! This is my son's car so I don't really think about it much. He still has the problem. I tried all the things you all mentioned and no luck. I also added a second ground cable just in case I had a weak ground somewhere. No difference. The ignition switch is new too and so is the starter relay. I can't think of anything else except replacing the harness. It is not simple so I rather not have to do that. Can anyone think of anything else? Thank you.