Contour Enthusiasts Group Archives Forums General Troubleshooting starting problem, new puzzle

This is a continuation of the starting problem described here:

http://www.contour.org/ubbthreads/showflat.php?Cat=&Board=trouble&Number=624240&page=2&view=collapsed&sb=5&o=7&fpart=1

I thought it was the starter, so I went to have it and my battery bench tested. Both turn out to be fine.

I unhooked the alternator just to be sure that it wasn't causing any problem on the power line. Still, won't start... I hear a click like the starter attempts to engage but everything powers down in the vehicle.

I check every ground connection in the car, clean up all the connections. No change.

So, I check the voltages.

Battery ~ 13 range
Positive cable before starter - same
Positive cable after starter - same
Positive terminal on starter ** 2 volts ** ????

Could it be the battery cable's starter plastic molded connector faulty? Causing too much resistance? It kind of makes sense the starter won't engage much at all with only 2 volts going to the connection, just enough for it to click.

Does anybody no for sure if there's anything inside this plastic molded connector that limits the voltage to the positive terminal until it tries to start? Doesn't seem it should be so, but wanted to be sure.

This battery cable probably has an outrageous price since Ford in their wisdom couldn't have made it a little more universal and friendly so you don't have to replace the whole thing.

Any insight anyone? Maybe someone in the mood can verify the voltage at the terminal or knows for sure?

TIA

I would pull the starter again and try cranking it while its connected to its wiring...maybe the starter is getting stuck on the flywheel...these cars do burn up the flywheel at times. Just pull the starter and leave it connected and ground it to the casting to see if it cranks.And while you got it out...inspect the flywheel teeth, the click you could be hearing is the starter trying to engage and jamming on the flywheel...just a thought, but could be worth looking into.

It happen to me one time when we install rebuilt torque coverter and valve body, without knowing, the bolt on the starter(10mm) came loose, the stater crank for a while then die.

I don't know what year car, or where you live, but when I lived in the NE, I've seen many good looking battery cables that are bad internally. After replacing, I cut the old one open and found corrosion throughout the cable and under the crimped ends. Salt does wonders to the wiring.