Finally got the top mounting bolt loose by using a breaker bar, but had to find a wobble extension of just the right length to go between the deep socket and the breaker bar. The starter is now off of the vehicle and ready to take to AutoZone in the morning to get it tested and, presumably, buy a replacement.

Should have this wrapped up later this morning!

 

First of all, I have to say I'm a bit embarrassed to admit that I put in a new starter and had the same problem I started with, but I'll do so in the hope that this will be a cautionary tale for future readers. The minor consolation for me is that the starter I replaced was the original factory unit on this vehicle with 140k miles on it, and when the guy at AutoZone tested it, he said it passed, but the tester doesn't evaluate "load", and that he had heard it rattle, suggesting that it was possible that the bearings were going bad (something along those lines). He warned me that the new starter would not be returnable for a refund if I installed it, but I took the chance and paid the $100.

In the back of my mind, I kept going back to the day the problem started. It was a warm (low 80's) day and dry. I'd made several trips around town that day, with the last stop at a store I spent maybe 20 minutes in. At no point prior to the problem occurring had there been any hint of the starter failing to start the van. From experiencing several immediate starts that day to one where you hear only a click. All of the accessories worked, the power windows and locks, stereo, lights, etc. I remember thinking, well everything else is working, so it must be the starter.

Anyway, today, I put the new unit on with relative ease, at least compared with taking off the original unit. I checked all of the connections twice, went to start the engine and, click. The dreaded click. I called a local shop to ask if they had anyone with electrical expertise, and the shop guy said yes, what kind of trouble are you having? So, I gave him the whole spiel. "You can have it towed in here tomorrow, and I'll be able to diagnose and repair it for you, but I'm 99% certain it's a connection problem somewhere. I can't count the number of customers who have brought in their vehicle with the same type of symptoms and the problem turned out to be dirty or loose connections." When discussing all of the other things that were working, he said "you have to remember that the starter requires a LOT more amperage than all of those other things." I thanked him for his advice, and sighed as I hung up. I had already cleaned the battery posts and clamps as one of the first things I did to resolve the problem. But the man's advice stuck with me, and I pulled the clamps off again. This time, in better light than the first time, I noticed a lot of corrosion on the postive cable, not at the post, but where the cable attached to the clamp, about an inch down and somewhat out of sight. As I was cleaning that out with baking soda and water, I noticed another corroded part of the cable further down.

The positive cable at the battery splits off three ways about four inches from the terminal. The plastic sleeve on the middle-sized one had considerable wrinkling, so I peeled back the sleeve to find significant corrosion, probably one third of it "gone". (Based on the direction this cable headed in before disappearing from view, I believe it is the cable that feeds the starter.) I cleaned off all of the corrosion as best I could, then soaked it in WD-40, hooked up the battery. Immediate ignition. Several times. While I was kicking myself, I kept wondering how the van started (with ZERO hesitation) several times the day problem began. I figured there'd be an episode or two of the starter hesitating before going right to the single click. I figured wrong!

Although the van has now started five times since I "fixed" it, I'm still going to take it in to determine what to do about the cable corrosion, cuz I figure that's only going to get worse as time goes on. I won't be attempting that repair, as I've exhausted my automotive DIY ambition tank for the month.

 

I would like to add that:
1. he could just repair the Solenoid.
2. This starter is a Nippondenso starter and can be repaired easily.
3. All you need to do is get the three parts that go bad in the Solenoid the Plunger and the 2 contacts.
4. You can get these and see a video on how to replace these parts in your starter at http://www.nationsautoelectric.com/densoparts.html
5. Just putting in my 2 cents these starters are very durable and will out last the vehicle itself and be put in another vehicle and out last it too the only thing that will NORMALLY go wrong is the Contacts Burn out $35.00 + or -
6. I have run this route on 3 different vehicles repaired them all the same way just put contact in got them from Nations.
7. Removal is always a pain but fixing the contacts is rather easy. good luck every one.