Chrysler Repair: 96 LHS 3.5L wont start, solenoid starter, solenoid switch


Question
When you turn the key the starter will not turn over. I can hear a click that I think is coming from the solenoid that only clicks once each turn of the key. The battery is fully charged and I tried a second battery to make sure that was not it. In looking under the car at the solenoid/starter, I am not sure how to get it out once the bolts are removed. It does not look like it is going to fit.  Any suggestions of other things to try, before attempting to remove the starter. I read some of your other post and made sure it is in park and tried to go between park and reverse and that did not change things

Answer
Hi Tim
If you hear a click coming from the engine, when you are in the cabin, then that is loud enough to be the solenoid switch on the starter motor proper. It verifies that the ignition switch, starter relay, and safety interlock are working properly. The only three reasons for no starter action is that the fat red cable from the battery to the solenoid is corroded/loose at either end, the contacts in the solenoid are oxidized, or the starter motor brushes,commutator,or field coils are impared. The latter two reasons require removing the starter/solenoid unit so I would begin by inspecting the red cable/clamp/battery interfaces and similarly at the solenoid. If you find nothing remarkable then R $ R is you next step. I like to take original units to a local rebuilder rather than to buy somebody else's unit at a part store.
There is nothing tricky about removal in a '96, at least according to my '94 shop manual for the 3.5 with Melco starter. The one trick is to first remove the bolts that secure it, then manipulate it so the solenoid can be reached more easily, then remove both wires from the unit, and finally remove the unit completely.
By '98 the procedure was a bit more complex, so I include that in case it might apply to your '96:
After disconnecting battery and raising the vehicle,
remove one nut on the catalytic support bracket.
remove two nuts from catalyst support bracket mounting.
remove two bolts and one nut attaching starter to engine
remove battery positive feed wire
remove starter solenoid assembly from trans housing
position starter to gain access to posi-lock wiring connector
position jack stand beneath engine and slightly lift to relieve pressure from left engine mount (use wood block spacer to protect pan)
remove three left engine mount mounting bolts from engine block
jack engine up slightly to give more room to maneuver the starter
slide rear of starter out between catalytic converter and engine mount
disconnect posi-lock starter solenoid connector
remove starter

Install is the reverse.

Please let me know if you have to do the latter procedure to get it out. Thanks
Roland