Recently, I had my 2002 Volvo XC V70 in for a fuel valve/pump repair/replace because the car wouldn't start. I also had the battery replaced (3 1/2 years) also. When I picked up the car, the repairman informed me that the car's starter had a flat spot and wouldn't turnover (possibly burned out connectors)> Previously, the car didn't have this issue. Also he showed me how to use a long screwdriver/hammer to tap on the outside of the starter housing while someone turned the key in the ignition to get the car started. Is this normal?

 

I would say it's relatively normal. Starters don't last forever, but most of the time they're pretty reliable. They are extremely primitive the way they're made, because you only use the thing 1 or 2 seconds a day.

 

I agree. If banging on the starter makes it work, replace the starter. There is a slight chance your attery is just weak enough to pass the tests but can't overcome some sort of resistance in the starter motor. Batteries only last about 4-5 years anyways.