Hi everyone.
I have a 2006 Grand Caravan 3.3L. The car is having a no crank, no start issue, only a single click when I turn the key. This usually indicates a starter problem. To be sure, I tested and ruled out the battery, starter relay, ground, voltage drop test on the battery cables, voltage test on the trigger post.

I replaced the dead starter with a used one (not rebuilt). Turned the key over, success! Drove it to my friends house (10 km). Everything seemed fine. Got home, got out of the vehicle and noticed a burning smell and smoke (very little) coming out of the hood. The temperature gauge was normal. I tried to start the car, no crank no start, single click just like before. It was late and dark, so I called it a night.


The next morning, I did another visual, checking for burnt connectors and noticed a frayed cable.


Cable is completely severed. Looks to me like a ground cable?



Wider shot, the frayed cable is on the passenger side.


Does anyone know what that frayed cable is for?

Once again, I ran the same tested indicated in the beginning of the post, everything passed. Just to be sure, I replaced the battery with a new one. Turned the key over, no crank, no start, single click.

Question is, is something killing the starter or was it just bad luck and I got a dud starter?
My priority right now is to get the car up and running and then work on tracking down the source of the smoke and overheating.

To sum it up.

1. Car wouldn't start. No crank, no start, single click
2. Ruled out the battery, relay, ground, cables to the starter.
3. Replaced the bad starter with a working used one.
4. Car start
5. Drove to friends house. Everyting fine. Drove back home, noticed smoke (very little) and burnt smell.
6. Car won't start, no crank, no start, single click
6. Noticed frayed cable, indicated in picture.
7. Replaced battery with new one. Tested relay, ground, cables to the starter, all pass. Car still won't start.

 

I've been having very similar problems with our 2001. The issue seems to be the ignition switch because if you jam the key all the way in, the starter will engage. I've put some graphite in there and it seems to have solved the issue for now.

 

I jammed the key in as hard as I could.. turned it over.. and.. it worked!! Thanks for the great tip. About the graphite method. Did you just spray the key hole with graphite? Would WD40 work?

Now that the car is starting, can anyone identify the frayed cable in the picture?

 

That's a grounding strap for your van's electrical system. Have it replaced asap.

 

I would not recommend WD-40. The best is Lock Ease but I couldn't find it around here so I bought a tube of powdered graphite and put some on the end of the key.

 

Thanks! Replaced and car is now back on the road

 

The fix was temporary. It had worked perfectly all summer and then started acting up today. It's not worth getting stranded somewhere so I ordered a new switch. I tried our spare keys and they didn't work either.