Jeep in question is on my site below. 85 cj7 with a 304 from a 76.
> I googled the archives and found a bunch of similar problems listed, but
> mine is a little different. I got the jeep running yesterday and went
> driving around town. After a few stops I picked up the kids at daycare. With
> them both buckled in the rear seat I turn the key and get a slow groan and
> then a click. I think, hmmm, that new optima battery is crap, not worth the
> money like the guys on the ng said. Then I look at the volt meter it's at
> 13. I get a guy to jump me and after letting the thing charge for several
> minutes I get the same click. Lights are strong, volts now at 14+,
> everything electrical works.
>
> I start looking under the jeep and found the lower starter bolt was loose
> and I think, hmm the starter is jammed...I tighten the starter, and try
> it....click. I bang on the starter with a hammer....click.. The kids are
> getting restless, I rock the jeep back and forth in gear to try and turn the
> flywheel .....click. I finally give up and get a ride home. I return with my
> truck and tow the jeep home. Luckily I had the tow bar already in place on
> the jeep.
>
> Today I remove the starter from the jeep and lay it on the front spring,
> turn the key and...click. I replace the relay on the inside front fender
> with an old one I had laying around....click. I completely remove the
> starter from the jeep, wiring and all and still get the same ....click. I
> had thought the "click" was the solenoid pushing the starter gear into
> place, but I guess not since the starter is now gone and the click is still
> there. What is the click? Oh yea, the volt meter drops to below 0 when I get
> the click.
>
There is a relatively light click that comes from the relay that is bolted to the fender. There is a very heavy click, clunk really, that comes from the starter motor itself. This is the solenoid that is throwing the starter gear into the flywheel. Normally the part on the fender fails, the contacts inside burn up. It clicks closed to pass high current to the starter, but since the contacts are burnt the juice doesn't flow.
All battery cables are new, the battery and starter is new, connections look
> good and tight. I'm going to check the ground strap from motor to frame
> tomorrow. I don't have a strap to the firewall like some, but I'm thinking
> of adding one. Also, I am taking the starter to get tested and/or return it.
> I hope that is it, but by reading some of the archives, I kind of doubt it.
> Any other suggestions?
>
It is sounding to me like you have a shorted winding in the starter motor. I recently had one of those. My Jeep would still start if I could get it rolling and dump the clutch. When you are at the store, check the new starter thay the pull off the shelf for you, when I was there the new motor was also toast and the guy had to go back and get yet another one.