Glad you checked the terminals at both ends for corrosion. I was wondering if you checked the resistance in the cables yet? Is this what you meant by clean? You also stated repairs are up to $600 but I don't know what parts have been tried yet.
If you have eliminated the cables here are some other ideas.
1) This is tricky unless you are in a shop with help at hand. Carry a small ball peen hammer with you in the car. Next time it acts up, someone will need to hold the key in the crank position while you tap, not bang, the starter solenoid. If it fires up you have an intermittent starter failure.
2) Starter relays. All relays can be checked by exchanging it for a similar one driving a different device. If your problem goes away the component using the defective relay will act up intermittently. These are fairly inexpensive, and since I don't have a picture of your fuse block to see if you have a similar one, buying it is a cheap way to check.
Tuesday, November 17th, 2009 AT 5:50 PM