Intermittant no start

I've been chasing an intermittant no start issue on my stang. I'll go to crank the car, turn the key and nothing happens. I can hear the fuel pump and the solenoid clicking but nothing else happens. If I keep cycling the key (on-off, on-off) eventually it will crank. I've replaced the following items in this order and nothing has fixed the issue.

replaced the clutch safety switch
replaced the ignition switch
Had the starter checked
replaced the 5 year old battery
replaced both positive and negative battery cables
replaced the starter solenoid

I'm at a loss as to what could be causing the problem. Any help would be greatlly appreciated.

thanks,
 
Obviously, you are going to have to wait until it won't start to do the troubleshooting. In that case, print the list and stick it in the glovebox, or with the tools you carry with you.


Since some of the tests will bypass the safety interlocks, make sure that the car is in neutral and the parking brake is set. Becoming a pancake isn’t part of the repair process…

Check battery, terminal connections, ground, starter relay switch (also known as solenoid) and starter in that order. The clamp on with 2 bolts battery terminal ends are a know problem causer.

A voltmeter is handy if you are familiar with how to use it to find bad connections. Measure the voltage drop across a connection: more than .5 volts across a connection indicates a problem.
See http://www.fluke.com/application_notes/automotive/circuit.asp?AGID=1&SID=103 for help for help troubleshooting voltage drops across grounds.
fig-7.gif


1.) Will the car start if it is jumped? Then clean battery terminals and check battery.

2.) Check the battery to engine block ground, and the ground behind the engine to the firewall.

3.) Jump the big terminals on the starter relay next to the battery with a screwdriver - watch out for the sparks! If the engine cranks, the starter and power wiring is good. The starter relay is also known as a starter solenoid.

4.) Then pull the small push on connector (red wire) off the starter relay (Looks like it is stuck on a screw). Then jump between the screw and the terminal that is connected to the battery. If it starts, the relay is good and your problem is in the rest of the circuit.

5.) Remember to check the ignition switch, neutral safety switch on auto trans and the clutch safety switch on manual trans cars. If they are good, then you have wiring problems.
Typical start circuit...
Diagram courtesy of Tmoss &Stang&2birds
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See http://www.autozone.com/images/cds/gif/large/0900823d80195963.gif for 88-90 year cars .OR see http://www.autozone.com/images/cds/gif/large/0900823d80195964.gif for 91-93 year cars. See http://www.autozone.com/servlet/UiB..._us/0900823d/80/1d/db/3c/0900823d801ddb3c.jsp for 94-95 model cars.

6.) The starter may be hung, loosen up the bolts that hold it on, and give it a good whack with a big hammer. Tighten up the bolts and try again.

7.) If that doesn't work, use a jumper cable from the positive lead on the battery direct to the starter post where the big wire from the relay connects. If it cranks then, it is the power wire from the relay gone bad. This will be hard to do, since there isn't much room to do it.

8.) Pull the starter and take it to Autozone or Pep Boys and have them test it. Starter fails test, then replace it. If you got this far, the starter is probably bad.
 
Well, it looks like the problem has been discovered...

I took my starter (which is the original starter for the car) to a place that actually rebuilds them and upon inspection the brushes were just about gone, which would cause my intermittant starting problems.

It will be nice to finally have this issue fixed on my car. Now to work on the rest of the issues. :D