Subaru Repair: 1996 Subaru Outback 2.5 - A year and a half.search for a resolution has yeiled nothing!!!! The problem is still here!!!!, subaru outback, heat increases

Question
Ok, and thanks to everyone who will read this and respond.  This problem has puzzled many a people over the last 18 months and I haven't received a remedy (though I tried them all) to fix the problem.  So here is the situation.  When I drive my outback from work on a WARM day, and I let it sit (for example, run it for about 30 minutes and go in to a store to pick up some groceries) I come out and turn the key, I get NOTHING.  No noise, no click, click click, just total silence.  This problem ONLY exists in the summertime when the weather gets above 70 degrees and the engine gets warm (last reading was about 125 degrees when it happened).  I have tried many of suggestions on this, from shift lock changes, cleaning the starter terminals and re-greasing them with electronic grease, to a new battery, alternator and starter......all have failed to correct the problem.  

The problem is there is something slowly failing and definitely impacted from the heat (since this is only a summertime problem)  The only way that a non car guy could explain this would be to relate it to a fuse…..when the fuse gets hot it opens and circuit is not complete.  When the fuse cools down the circuit is once again made and I am able to use my key to start the car.  Since dealing with this over the last 18 months, the AAA guy showed me how to start my car by turning the key to the on position and taking my pocket knife and "jumping" the lead wire from the battery to the starter bolt (both near the firewall).  Once I do this, she fires right up and off I go….  

I have been chasing this problem for about 1.5 years now and no one can tell what to do.  We have just hit a few hot days here and I am dealing with the problem almost weekly.  Any help would be appreciated!

Dan

Answer
Dan,

Sounds like your frustrated ,but the car is very fixable.Heat increases resistance the more resistance you have the harder it is for electrical current to flow through a given circuit.What needs to happen instead of a parts toss is a analisys of the problem.When the car fails to start.Voltage and voltage drop tests need to be done on the positive and negative cable as well as the wiring from the ignition through inhibitor switch ,relay to the starter.Until all of this is done the problem will go undiagnosed.A poor connection somewhere or a corroded bit of wiring will cause your problem.But its not an easy task or a do it your self type of gig.Even half of the repair techs out there may have trouble pinpointing it.I wish i could make it simple for you but its just not a simple task on intermittent electrical issues.I Would suspect the relay under the drivers side of the dash way up under the dash.But thats the only Guess i will make.I would inquire around and find someone who has a repor for electrical issues not the average shop even better would be an independent Subaru shop like mine


Justin
All Wheel Drive Auto