No Click, No Start 78 Cj5

i agree with pete it sounds like a bad/low voltage event somewhere isolate one thing at a time .

 

There are poor, good and better solenoids available for our '78's I always opt for Blue Streak whenever I'm delaing with automotive electrical. Here's a glaring comparision of the foot of an old Echlin and a Blue Streak.



As we all know copper conducts electricity more efficiently than aluminum, but then even copper can't have continuity throught a painted fender.
Another thing about these Ford style solenoids, don't go ape when tightening down the primary contacts, it is possible to bend the internals to the point of contact, making the starter spin continuously.

 

Here's a thought and as an electrician I have seen this a few times on 3phase AC motor starters.. It is possible that the 11 volts and the current to the solenoid coil is causing the contacts to close too slow and they weld shut. Or they are pitted and still weld shut from arcing. So to speak. If it were me I'd remove the coil wire at the solenoid, and using a jumper with alligator clips connect the coil wire to the solenoid post. Now if it sticks, pull the alligator clip off and see what happens..

As others have stated make sure you have a solid ground with the correct size wire.

 

That link is excellent. Thanks Tim!

 

After checking every wire in the plugs to the ignition switch, the red w/ tracer was always on in the start position, the blue was activated only when start position was engaged. (backwards from almost all diagrams I have found) I wired the red w/ tracer directly to the igintion bypassing the solenoid and put the blue on the s terminal. It works great now, no more sticking. I have nothing on the I teminal now, but it WORKS!

 

The ground is through the mount, but I ran a secondary ground wire from the mounting bolt directly to the negative battery terminal to make sure. ground is good.