Chrysler Repair: Intermittent Starting, starter solenoid, chrysler voyager

Question
I have a 2001 Chrysler Voyager, 3.3L V6, with 103K miles.
When attempting to start the van, there is a loud click
coming from the front of the engine compartment, but the
starter will not engage. I attempt to start the engine
without success 9 or 10 times (or sometimes more), and
eventually the starter engages and the engine starts up.  A
short time ago, I replaced the battery and starter relay.
Prior to replacing these items, the engine would from time
to time keep running after the ignition key was turned off,
with the engine making lots of noise.  The engine would only
shut off after turning the ignition on and off a few times.
Any suggestions as to what I need to do to get consistent
starting?  Thanks.

Answer
Hi Anthony,
The loud click is the sound of the starter solenoid which has the function of connecting the battery to the brushes of the starter motor. That means your problem is either the battery power is too weak (but that was replaced and presumably if you aren's showing a battery warning light when driving then the alternator is recharging it), or the fat red wire from the + post of the battery to the starter motor is not cleanly connected at the cable/clamp interface or the clamp/battery interface or the cable/starter motor interface, or the ground wire from the - post of the battery to the rear of the engine block is not cleanly connected at both ends, or finally that the starter motor/solenoid have worn brushes/corroded contacts and need to be replaced. All things being equal it is probably the starter motor/solenoid that is at fault, but all the other possibilities are something that you can check yourself at no cost. So I would recommend you do that, and if all seem OK then getting the starter motor/solenoid rebuilt would be the next option. I prefer having the factory motor rebuilt at a competent shop rather than buying an unknown factory rebuilt unit. The failure of the starter to disengage as you describe is also indicative of a work
bendix unit in the starter motor which is supposed to disengage the starter once the engind starts. For all these reasons I believe you will end up doing the rebuild. Removing and replacing the motor is straight forward in your particular vehicle, except notice a thin spacer between the starter and the flange on which it is mounted and be sure to reuse that when installing. To avoid a burn, be sure to disconnect the - post clamp from the battery as the first and last steps of the job.
Roland
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