My 93 Astro did that nonsense. I replaced the starter and it has been fine ever since.If you hear a clicking sound when trying to start, or the starter turns the engine over slowly there are several possible problems to consider. 1. A starter with excessive current draw. 2.Poor or corroded connections at the battery and/or the starter solenoid ( this would include the condition of the cables themselves).
Start by inspecting and cleaning the battery connections, and then check the battery's state of charge. If you hear a clicking sound when trying to start, it generally indicates low voltage to the starter. this is often due to bad cable connections. In some cases it is a starter solenoid, but much less often than people think. Sometimes dirt combined with battery acid becomes conductive and can actually put a slow drain on the battery. Does your battery pass a load test? If nothing happens when you turn the key, try turning on the headlights. Do they light? If they light, try starting the engine with the headlights on while someone observes them. Do they dim down and go out or almost out? If they stay bright, you may have a safety switch problem, like an out of adjustment or defective neutral safety switch. To verify neutral switch problem, secure the parking brake and place your foot firmly on the brake pedal. The next time it does nothing use one hand to turn and hold the ignition key on while moving the gearshift lever slowly through its entire range. If suddenly the starter goes you have a neutral switch out of adjustment. If neutral switch tok, next test for voltage drop or loss.This tests condition of the cables.On most tests, 0.2 volts is usually the most allowable voltage loss on a 12 volt system.Disable the ignition so the vehicle can't possibly start.If using an analog voltmeter connect the positive lead to positive post and negative lead to the neg post. Digital meters will function regardless of polarity.Connect meter to the battery's positive post and the other to the starter solenoid stud. Have someone turn the key to start and observe the reading. It should not exceed 0.2 volts.If it does, you can narrow down your test points, and perform the same test with one probe connected to the cable clamp while holding the other directly against the battery's post. Undersized cables will also give you a high reading, and don't be fooled by the thick vinyl coating over the copper wire. You then will check the ground side negative battery post one lead with the other connected to the starter housing. Once again it should not exceed 0.2 volts.On most astro van starters there is a connection at the base of the solenoid that passes thru a rubber grommet into the starter.Be carefull not to touch grounded surface. Once again should not exceed 0.2 volts. If it does replace solenoid. Good Luck
