Hi folks,
I spoke too soon.
Please help!!! I am at wit’s end and about to throw in the towel.
I am having trouble getting the starter to engage the flywheel. Here's a clip of the sound for your entertainment
https://youtube.com/shorts/I8QA57wKh3E.
Since the inception of this build (~10 yrs ago), I have had intermittent issues with the starter pinion gear not engaging the flywheel. It spins up but often doesn’t engage the flywheel (e.g., two or three attempts before it actually engages).
I installed a new starter years ago but experienced the same issue.
I tried a washer shim but basically had same issue.
Just recently, however, I can’t get the starter to engage the flywheel
at all. It spins up but no engagement whatsoever. Since I had been working on an electrical issue at a different part of the car, I thought the total lack of starter & flywheel engagement may somehow have been related.
Background: The engine is a small block chevy (350cui) connected to a 5 sp Audi trans) via an adapter kit from Kennedy Engineering. The kit came with an adapter plate, TOS112 Starter (used in Toyota trucks), 112 tooth flywheel (which Kennedy Engineering built), Audi Stock Pressure Plate, 240mm, disc and tob. The starter mounts to the adapter plate.
Here are the following steps I have taken to try and determine the cause:
1) Load tested various electrical pathways of the starter system, Result – don’t believe I have an electrical problem, but I’m not a mechanic… (please see attached results).
2) Added extra grounds from block and frame to starter mounting bolts to ensure adequate grounding. Result – no difference.
3) Removed the starter and put in another one that I had laying around. Result – same observation – spins up but no engagement.
4) Bench tested the starter off the car. Result - seems to work just fine.
5) Bench tested the starter on the car. Result - seems to work just fine.
6) Moving the flywheel (~25°) manually (by rocking car forward in gear) to see if it could be out of round. Result – no change.
7) Paper witness test – taped small piece of paper to flywheel. Activated starter. Result – Piece of paper disappeared. Can’t find it. Won’t do that again…..
9) Finally, I also shimmed starter mounting bolts (using washers) to tilt Bendix towards and away from flywheel.
a. Left side - 1 washer, then 2 washers, then 3 washers. Result – same observation each time, no engagement.
b. Right side - 1 washer, then 2 washers, then 3 washers. Result – same observation each time, no engagement.
c. Note: this type of starter should not be shimmed but I thought I would give it a shot.
Is there something I am missing here? Are there any other tests I should perform to help identify why the starter will not engage the flywheel?
Any recommendations or advice is welcome. Thanks.