1994 Ford Ranger 4x4 4.0L Manual transmission No crank Issue
When you first attach the battery cable, you can turn the key to start and there will be a loud click (or clunk) at the starter. Then nothing no matter how many times you turn the key.
Disconnect the battery for a second or two and then it will do it one time again.
You have to keep disconnecting the battery between every try.
The motor will turn over ever so slightly at each clunk.
After five or even twelve times (clunks), the motor will turnover and start. The motor runs great.
Maybe one or two times after starting, the starter will engage when you try it again, but then soon, you will go back to the clunk sound with no crank.
The same will happen if you bypass the ignition and clutch safety switch and use a remote starter switch and send a signal to the starter solenoid on the fender. It doesn’t matter if you bypass the ignition, you will still get the clunk. But it is easier because you are right beside the battery to pull off one of the cables to try again.
Battery is new. 12.68 volts Starter solenoid is new, twice. Start is new (rebuilt) twice. Starter works great outside of the vehicle. Added a second ground wire to other mounting bolt on starter. Replaced all relays in fuse box with new ones. Starter solenoid works properly. 12.68 volts to solenoid. Cleaned all contact rings with emery cloth.
Only thing I haven’t checked is voltage at starter to be sure the power lead from solenoid is getting to starter. Will do that this evening. Might run a direct hot lead from battery to starter power post to see if it works every time.
It acts like starter doesn’t have enough amps to turn engine over. Might pull all spark plugs to see if it will turn over without compression.
Any help would be appreciated.

 

Spoke with an "old" mechanic. He said he always had problems with the starter solenoid on the fender losing ground.
Made a ground wire, from battery negative and mounted it to the solenoid. Starts everytime!