Saturn Repair: 1997 Saturn (Wont Start), jumper cables, battery cables


Question
I drove the car about two days ago.  Started fine and drove without problem.  I stopped the car at a friends house and went in for about ten minutes.  When I tried starting it again, it wouldn't start.  It made the clicking noise like it didn't have enough power.  We tried jumper cables (no success).  Popped the clutch and got the car started.  On the way home it was idling very low and would die if you let off the gas.  I let the car sit for one day.  I went out the next morning, and there was nothing (no sound no click and very little interior dome light).  I checked the wire connections, they all seemed to be fine.  Removed the battery and alternator and had them tested (they were both bad).  The alternator was pushing almost 20 amps.  My understanding is that they usualy fail on the lower side under 11 or 12.  Replaced both the alternator and the battery.  Car still won't start.  Removed the starter and had it tested.  It didn't seem to have any problems.  I have now reinstalled the starter, but the car still won't start.  It makes the clicking sound like it isn't getting enough power to turn the starter.  Do you think it's possible that my alternator caused some problems with my battery cables?  I am going to get the new battery tested and then replace the positive battery cable.  Oh, I have also replaced the clutch starter switch and that wasn't the problem either.  

Answer
Bobby,
 Thank you for the well worded question.  You wouldn't believe how many times I get a question like, "Why won't my car start." Anyway, it sounds to me like you have a bad starter, or better yet, a bad spot in the winding of the starter motor.  If the starter works 9 out of 10 times and then quits one day and works the next, that is most likely your problem.  When you get the "clicking" noise like it doesn't want to start, keep trying.  Cycle the key repeatedly between start and run and the motor should unstick itself.  If this is the case, then a starter replacement is in order.  I have seen this happen many times.  As far as your alternator causing problems with your battery cables, this is not likely.  However, if you will look at the smaller gauge wire on the back of the alternator, about six inches away from the alternator, you will see a two or three inch section of wire that looks like it has some heat-shrink wrapping on it. (This wire runs from the alternator to the starter) This is called a fusible link.  If your alternator output surges above a specified limit this link will burn out causing a zero power output condition.  In my experience, it is always wise to replace this link any time the alternator is replaced.  You can pick a fusible link up at your Saturn dealer for around 15 bucks. Rarely, only when corrosion is an issue, does a positive battery cable go bad.  Check the battery bolts for corrosion and correct threading.  Hope this helps!
Chris Greiner