1998 5-speed Legacy Outback starting problem

I'd try tapping on the starter when it doesn't start, and see what happens.

Thanks- and if the tapping on the starter helps, what does that tell us?

If the battery is more than 5 years old, replace it and see if the problems goes away.

I still say change the battery if it's older than 5 years. The problem is intermittent and the test might have just not caught the battery misbehaving.

I had a very similar problem. I swore it was the starter, it was the battery. It's up to you....

Moving the car manually with the transmission in gear should change the orientation of the flywheel teeth to the pinion gear on the bendix drive of the starter motor. The pinion gear teeth may not line up properly any longer for some reason and instead of meshing, click against the flywheel when you turn the key to the start position.

Do you get a "click" for each time you turn the key to the start position? If possible, listen to where the click originates. Of course, you don't want to jump, or have your fingers somewhere unwise in case the motor decides to turn over when you are trying to determine just what is going "click" when your motor doesn't turn over.

Tapping the starter can help loosen a stuck solenoid or bendix drive and possibly shift internal bits just enough to get current flow for another start, if the plunger contacts are worn. Don't overdo the tapping / beating, as there is always the possibility to damage internals such as motor magnets.

~Brian

Brian- Thanks for your time and careful explanation. I will post a follow up when we figure out how to remedy. Cheers!