96 Legacy Outback that doesn't like to start

[Karl Saal]

I have an on going electrical problem with our 96 Legacy Outback. When
you try to start it, it sounds like the solenoid clicks but nothing
else happens. After several attempts it will start as if there never
was a problem. I figured I had connection issues and cleaned the
battery terminals after getting the battery checked (it was fine) and
the car ran fine for a month or so then the problem returned. I have
repeatedly cleaned the contacts and got myself about 30 days each time
before the problem returned. Next (frustrated) I cleaned the battery
terminals, replaced the battery clamps, replaced the battery cables +
& - and cleaned the connections at the starter and the deadman switch
on the clutch. This got me 3 months of trouble free operation but the
problem has returned again. I work in electronics and I know my
connections are good. Am I experiencing a dead spot on the starter or
something in the ignition switch or what? I feel like there is a
resistive connection somewhere that is holding things up unless the
other connections are flawless and once there is any reduction of
current it isn't able to overcome the connection and the starter won't
work. Any Subaru gurus out there have any ideas about this one? I'd
appreciate any help. Karl

 

[GC]

Have a 96 Legacy and same problem...Turned out to be the starter
Sears actually found the problem

Gary

 

[Ken Parker]

This problem is commonly caused by a burned and pitted started solenoid
contact. I don't know if the solenoid is seperately replaceable on Subarus

Ken

 

[Robert L. Wilson]

The solenoid contacts on these starters (and Toyotas and lots of other
brands using Nippon-Denso starters) are notorious for this. The copper
contact metal gets worn away to the state where the moving contact does not
make good contact with both the stationary ones at the same time. You can
rebuild the soldenoid pretty easily. The official contacts are available,
but lots of us have made our own out of whatever copper was available. I did
the contacts on my '95 Outback a couple of months ago using copper from
copper pipe. I did the contacts on our old Plymouth Voyager, same kind of
starter and exactly the same problem, using a penny. The penny is better in
some ways, it is a harder copper alloy, but it is not big enough to replace
the whole contact and must be soldered into a recess you machine in the old
contact, then cut to shape.
Bob Wilson