2008 Veracruz - Strange noise.

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I have a 2008 Hyundai Veracruz and I am having an issue with it that the dealership can't figure out. they said they tried to start it about 100 times and it never made the noise but when we started it the day after we got it back from the dealership of course it made the noise. it is making a strange noise sometimes loader than others when we try to start the vehicle. I thought it was the starter sticking engaged but it wasn't because I changed the starter and it still is making the noise. when it makes the noise (not all of the time) it tends to be when it is cold. I am thinking it may be the ignition because it seems like it doesn't make the noise as much when you fiddle with the key. my wife had a lot of weight on her keys so I told her to take all of the extra weight off of her key ring because I think possibly the weight is causing the ignition to loosen and have contact issues. does any one have any ideas if the ignition is the problem or what can be done to solve my issue.

Mr_Shiftright

So you're saying your starter motor is hanging up? That is, this noise sounds just like when you try to start the car with the motor already running?

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I thought it was the starter but I changed the starter and it is still making the noise. yes the noise sounds like the starter sticking but it isn't. now the car has problems starting at times (clicks).

Mr_Shiftright

What makes you think it isn't sticking if it sounds like it is? What I'm driving at is that a chewed up flywheel can cause a new starter to hang up. Also if you hear the solenoid clicking in the starter, this suggests to me that your new starter might be a rebuilt, in which case (depending where you got it), it might also be defective.

Weird thing is, a starter can bench test ok, but not operate when bolted up.