Starter issues

[Kidshorsesme]

Have an issue with the starting system on my 2006 CRD that I'm struggling to diagnose & fix. When you turn the key 'On' & start, all works as it should ! When you turn the key 'Off', it does stop the engine BUT it sounds like a metallic 'Clang' when you do. It sounds to me like the starter momentarily 'engaging' the ring gear when you switch off. Previously I had a 'No Crank' issue when attempting to start, you could hear the start
relay in the under bonnet fuse box 'clicking' but no start. I swapped out the identical relay next to it & it cranked & started immediately but still had the same 'clunk' on switch off.

The most obvious potential cause was the ignition switch, so I purchased a replacement with the correct additional terminal from RockAuto.com ... and it cured the problem ... for a while anyway. Now its back on EVERY shutdown. Also occasionally have a 'No Crank' situation ... so I'm leaning toward that problem being the actual solenoid on the side of the starter ? So will take the starter motor out & replace the entire starter. I'm not sure if this will solve the switch off issue though ?

Seems weird that when I replaced the ignition switch, the switch off problem went away for a while, but now is doing the same as before ? The actual ignition key / barrel seems reasonably 'smooth' without the ignition switch mounted on the back, but feels decidedly 'notchy' when its all back together.

Anyone else have an issue like this ?

[Kidshorsesme]

Problem Solved !

New Valeo starter motor fitted to the vehicle, and when diagnosing 'clunk' when turning off the ignition, traced the issue to the power isolation solenoid that allows power from the battery to the rear 'Anderson' plug ! The actual issue was ... when turning off the ignition, there was a small 'back flow' of 12v FROM the isolation solenoid 'engage' side that is hard wired into the 'Ignition On'. So replaced the isolation solenoid AND put a diode on the supply side FROM the 'Ignition On' to prevent ANY 'back flow' of 12v ever again !

This was the last big job needed doing on the WH to make it serviceable & reliable again !

Has been a big few weeks though changing out the following:

Front Struts x2
Both front lower control arms
Both CV's on the front drive shaft
Front sway bar bushes x 2
1x front outer CV boot & clamps
Rear shock absorbers x2
Full wheel alignment

Heading back off to work soon ... for a REST !