Chrysler Repair: Problems starting 96 Plm Gr Voyager, solenoid switch, motor armature

Question
I have an intermittent problem with starting our van.  Sometimes when I turn the key the solenoid clicks but the starter doesn't turn over the engine, other times it does, and sometimes it turns it over once and then stops turning it over.  Other times it turns and starts right up.  We put a new battery in a year ago and the lights don't go out when we try to start it.  I figured it was not the relay since the solenoid seems to engage but the starter doesn't always turn the engine over.  What would you suggest for this 3.3L V6 96 Grand Voyager?

Answer
Hi Karl,
So long as the solenoid clicks you have no issue with the relay. It then has to be either the large red wire connected directly to the  + post of the battery is not making good contact at the clamp to battery post interface, the wire itself is corroded and not conducting well or it is not cleanly attached to the solenoid switch, OR the starter motor armature/brush interface is worn/corroded so that the starter motor is not conducting the current from the red wire, or the contacts in the solenoid switch are corroded/oxidized and need to be cleaned/polished. You might also want to check the ground wire from the - post of the battery to the rear of the cylinder head to be sure it doesn't have any problems such as I described for the red wire, above. My suspicion is that he starter motor is beginning to 'go' due to age/usage, particularly if you haven't rebuilt it since new.
When checking any of the major wires, always begin by removing the - post clamp from the battery to avoid a short circuit. It is easy to change the starter motor on this engine, so you could remove it, take it directly to a shop that rebuilds starter motors, and thus re-use the motor that came with the van if it has never been exchanged.
I favor that approach as compared to buying one that has been rebuilt and whose history is unknown.
Roland
PS Use the 'thank/rate' tab below to get back to me without having to wait for me to be 'available to take a question. There is a space for comments, to which I will reply. While there, if you would like to put a 'yes' where you see "nomination?" I would appreciate that.