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My 408 project on my 91' has been going great. Untill recently when I turn the key I only get the single click from the starter solenoid. Jumped the battery and it cranks/starts, or sometimes I'll turn the key a few times then it turns over, does this even after a good drive (starter is hear wrapped, so not a hot start issue).
So I jump the solenoid and it cranks instantly. Replace solenoid with an extra one I knew to work previously, and same deal.
My question is do I just have two bad solenoids, or is my battery (4 years old, 850 CCA, 12.3V) just slowly dieing, or added resistance somewhere in the circuit? Terminals, cables, starter are new.
4 years is good life for a battery. What is battery voltage at rest and at running? At rest it should be 12.6 or so. Idle it should be between 13.5 and 14.5.
You can test the solenoid by pulling off that little slip on wire from your solenoid, then run a jumper wire from your positive battery post to that now bare small post on your solenoid.
If you jump the solinoid and the engine cranks, reliably and repeatably, than the solinoid is bad. If you turn the key and you get a single click, that indicates worn/burnt contacts in the solinoid, or bad electrical cable to the starter. If you turn the key and get multiple clicks, that's a low/bad battery.
you mentioned that the starter will crank when you jump the solinoid... So that means your starter and cables are good. Replace the solinoid.
If you have the funds and time, try to order a motorcraft solinoid... Or go on rockauto And buy the most expensive one they offer. Either way is better than AutoZone valuecraft junk.