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My Volvo guy that works on all my cars suggested that the starter needed to be rebuilt but I have a hunch that a relay is to blame due to that clicking noise I am hearing.
Hi Matt,
Turns out you are both right. The clicking noise is coming from a relay most often referred to as a solenoid. The solenoid relay is part of the starter assembly.
I wonder if your new battery ever got charged fully.
Before rebuilding or replacing the starter, some diagnostic should be performed, because starters aren't cheap, chain-store rebuilt units are often defective, and replacing them in cold weather isn't fun. Your trusty Volvo guy will know how to be sure the starter is the culprit, and not simply battery cables. And if he has your starter rebuilt instead of swapping in one from the parts house, you have a good shop.
If you decide to work on this yourself, be aware battery cables can corrode inside the insulation, most often inside the crimps at the end terminals. This can result in the "click, but no grr-rr-rr" symptom. Watch your dome light as you try to crank. If it goes out, suspect cables. If not, get a good size wooden stick or ball bat and rap the side of the starter (solenoid) once and try again. Cold weather makes things shrink.
--
Art Benstein near Baltimore
By the time a man is wise enough to watch his step, he's too old to go anywhere.
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