Engine/Transmission (1994 - 1998) Starter problem

[Bill Lins]

I installed new contacts in my starter about 3 weeks ago.



Yesterday, when shutting the engine down, it began making a loud "CLACK' sound as if the starter drive was hanging up on the flywheel. It now does it every time I shut the engine off.



The starter appears to be square to the bellhousing & the mounting bolts are tight.



There were no shims between the starter & bellhousing (like SB Chevys sometimes have) when I pulled the starter.



Does anyone have any idea what's wrong & how to fix it?

 

[Joe G.]

There is a clip on the end of the starter shaft. If it came off it might make this sound. I know of one that did come off. The starter gear managed to jam the torque convertor so hard that we had to pull the trans to get the gear loose. If this is what is wrong you want to fix it ASAP.

 

[Andy Redmond]

Your contacts were nice and square against the baklite material on the "floor" of the solenoid housing? Sometimes they get twisted/cocked when tightening the bolt that retains the contact.



Use a pin punch or blunt screwdriver to hold it square as the bolt is tightened. .



If it has deeper troubles send me a PM.



Andy

 

[Bill Lins]

Originally posted by Andy Redmond

Your contacts were nice and square against the baklite material on the "floor" of the solenoid housing?

They were when I installed them. I guess the bolts could have loosened up, but the truck starts just fine. Guess I'll have to pull the starter again & check them.



I appreciate y'all's responses- I'll let you know what I find.

 

[Bill Lins]

Update- not good

Pulled the starter today- the 3 week old plunger & contacts were burned & pitted much more than I would have expected.



The clip on the end of the drive was OK and there was no abnormal wear on the pinion or the teeth on the edge of the flywheel.



I installed LarryB's Super Contacts & plunger- starter still makes the same noise on shutdown.



I'm wondering if there is an electrical problem with the starter motor- any ideas?

 

[illflem]

Bill, about the only other thing that can go wrong with the starter motor is the bearings. If it spins freely they're probably ok.

 

[Bill Lins]

Mystery solved!

Well, I bit the bullet & bought a reman starter this morning.



After pulling the old starter (again) & laying the two of them side by side, I could see that the pinion on the old starter drive was sticking out about 1/4" farther than on the new drive. I could push the gear back into the housing but the spring would push it back out.



I installed the reman & everything works OK now. I haven't yet decided whether to turn in the core or keep it & try to fix it.



Thanks to everyone who responded.

 

[DDunse]

What caused the old one to stick out a 1/4 inch? I just ordered the contact kit and want to avoid possible trouble.

 

[Bill Lins]

Originally posted by DDunse

What caused the old one to stick out a 1/4 inch?

I don't know for sure- possibly something inside the starter had broken. The reman carries a lifetime warranty, so I let the core go back without disassembling it.



I wouldn't worry about putting contacts in- many have done it without problems. Apparently my problem with the drive was unrelated to the contact replacement.

 

[C. Harlan]

One thing to keep in mind, and I am toying with the idea of it myself, is a marine battery disconnect to the starter... In case it sticks, or for any other reason... I have had my share of starter problems, and just assume replace it with a reman, so that way it will work, under warranty!! Just my $. 02 worth!



-Chris-

 

[LarryB]

Originally posted by charlan

One thing to keep in mind, and I am toying with the idea of it myself, is a marine battery disconnect to the starter... In case it sticks, or for any other reason

I have these quick disconnect battery bolts on my site now just for this reason.

LarryB

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