shim starter?

[zachmac]

So I figured out my noise (see what the heck did I do thread) is the flywheel rubbing just slightly on the gear wheel of the starter even though the starter is fully retracted. The starter is a gear reduction unit that worked without issue before but since the rebuild I did swap to a lightened stock flywheel I bought used from a forum member. Has anyone installed a gear reduction unit and found the need for a shim plate? I can actually see the contact via the inspection plate hole. Guess that's one of the things you can inspect. It looks like I only need about a 1/16 of an inch to be good to go, if that.

One option it to just run it; either the gears on the starter or the flywheel (probably the starter) will quickly "grind to clearance" but that just don't seem like a good idea!

[vandor]

There was a small batch of GR starters that had the wrong gear on it. Only about 1 mm difference in how far the gear teeth come out, but that is all you need, I suppose. Contact the vendor where you bought the starter.
The other possibility is that you have too much end-play in the crankshaft and thus the flywheel has moved toward the front of the engine (along with the crank). Seems unlikely, but worth checking.

[So Cal Mark]

if someone lightened the flywheel perhaps they also machined the mounting surface which would move the flywheel closer to the engine. Not the best idea to lighten the stock flywheel. I've seen them fail after machining

[zachmac]

I'm thinking Mark is probably right, they probably slightly machined the mounting surface. I have to admit I didn't spend as much time taking measurements as I should have on the new / used flywheel. I don't think it is crankshaft play as I just rebuilt everything and replaced the thrust washers and checked the play while assembling and it was well within specs.

I hope the flywheel is going to stay together as it was already run for over 3k miles in the PO fairly highly modified car with no issues. I did inspect it for cracks, etc. and no visible issues. Mark, how many have you actually known to fail, you've got me worried now.

I also just put together another fact that indicates the mating surface must be machined. I noticed that when adjusting my brand new clutch cable with plenty of meat on the clutch disc, I was still almost at the end of the adjustment. If the flywheel is thinner at the mount that would make sense. Darn, now I think I really need to consider dropping the tranny and replacing it!

Csaba,

Can you tell me what the gear length should be? I can easily pull the starter (loose waiting for me to resolve right no) and measure it.

[zachmac]

Bit the bullet today and dropped the tranny. Sure enough the lightened flywheel had been machined on the mounting surface just enough to cause a problem. Shame as a simple plate shim there would have corrected it but in the interest of getting running I put back the stock unit for now. Man was that a full days work!

[So Cal Mark]

I suppose that's why the previous owner sold that flywheel

[zachmac]

I suppose that's why the previous owner sold that flywheel

Actually in his defense no. He lives in Hawaii and the tin worm just got the better of his car. I purchased several items form him and all are fine and I assume he either shimmed this flywheel, or his starter and just forgot to mention that. Again, a proper spacer between this and the crank of about 1 or 2 mm would solve the issue. Maybe if I feel energetic in a year or so I'll have this one magnafluxed and if it's good have a spacer made and re-install it. Right now I just want to get back to a running / driving car!

[DieselSpider]

How much will it cost to Magnaflux and then have shims made after which you will still have a flywheel potentially weak and thin where it bolts to the crank in a high stress area compared to the cost of cutting your losses and buying the $219 lightened flywheel from AutoRicambi:

http://www.autoricambi.us/product/EN8-4 ... RFORMANCE/

[zachmac]

Zero, brother-in-law is a machinist who works in a factory with all the right tools and they magnaflux parts all the time and they are okay with him working on personal stuff on his own time. Maybe have to share a glass of red wine or Cognac when he's over for turkey day!