Intermittent Start Problem 97gt

[97gter]

Hello fellow GTers - I have a nagging start problem with my 1997 Legacy GT 2.5 wagon (174k miles), AT. Sometimes it doesn't want to start - all the lights, blower, etc. come on strong, but no ignition. I can hear the clunk of starter. Usually, taking the key in and out of the ignition, jiggling it, and praying eventually works. The ignition switch and its wiring are original. It happens more often with a key copy versus the original. Here's some pieces of the puzzle to chew on:

 

The good: It recently had a full head gasket replacement by a Subaru specialist along with the radiator, all hoses, fluids, and throttle position sensor. All parts are OEM. The crank position sensor is also new within the past year due to a code being thrown. There are no other obvious electrical gremlins, the battery is new and cables are clean. The starter bench tested good. It appears to be original to the car, however.

 

The bad: This start problem previously was worse and also was accompanied by an electrical burning smell from the engine bay, leading to the crank position sensor being replaced along with the alternator and related belts. That seemed to have solved it along with the head gasket job, but it has returned.

 

Errata: Extensive googling revealed Subaru maybe made running changes in 1997 and my car may have some sort of interlock or immobilizer from the factory. The original owner bought an anti-theft alarm from the dealer, which is accompanied by the yellow alarm system warning sticker under the hood. At some point more than 15 years ago he had it removed. Trying to start the car in neutral doesn't help the problem. The local Subaru specialist (who is a masochist - he only does old Subarus and British cars) basically said he isn't sure where to find the problem as everything tests out. Temperature does not seem to affect the issue.

 

This person's question seems similar: https://www.subaruoutback.org/threads/intermittent-starting-problem.116314/

 

Thoughts? Thank you in advance!

[Brighton96]

I wouldn't rule out bad grounds, corroded wires inside the protective covers or a failing starter. When my starter began to show it's age it did sort of the same thing, just randomly wouldn't crank, only a click or sometimes nothing at all. Also 90 ish % of electrical issues are caused by bad grounds and our cars have subpar grounding from the factory. If the engine was out, there's a good chance one was left disconnected, even specialty mechanics do this from time to time. I would start with disconnecting all the grounds you can find, scrub with steel wool or scotchbrite, reconnect and test. Still not working? Replace the main ground cable from the battery to starter. Still not working? Maybe considering putting a new starter in.

[doublechaz]

+1 to the starter. There is a ring on the shaft internal to the starter. When the solenoid pushes the pinion forward into the flywheel (clack) this ring makes the high amperage connection needed to turn the starter by hitting a pair of tabs. The ring and tabs get burned a little on starting and by 150k to 200k it typically gives up. When it happens to land on a less burned part it works (and tests) perfect. If it lands on a more burned part it fails. If you are stranded somewhere you can often get it to work again by giving it a good hit with the end of an ice scraper or similar. Don't use something metal. I once saw a guy blow off his finger when his wedding band connected the big red wire to ground. Both the ring and the finger were no more than a dark stain in the engine bay.

 

When I first ran in to this starter problem years ago, money was a big problem. I was able to disassemble my starter and clean the ring and tabs and bend them slightly for better contact. That got me about another 15k miles. By then I could get another starter. It was not OE and did not last very long, a couple years. The OE I got after that lasted at least another 150k. It has done it a couple times more recently in hot conditions. I have a new OE starter in the foot well so I don't get stranded somewhere.

[97gter]

Thank you, folks! I had the starter replaced at the Subaru dealer in Frankfurt, Germany. They surprisingly had an OE one in stock - the high number of US servicemembers in Germany means a certain number of US models are driving around. Was it $1000 installed, yes. In any case, it (knocks on wood) starts right up now with no issue. I also followed you all's advice on the grounds - they were all quite clean and in-place.

 

We are shipping the car back to the US by sea quite soon, so she is on to her next adventure!