Atypical starter problem. I'm out of ideas

[hurgrave]

Manual and automatic starters are the same. Furthermore, the 2.8 starter is also the same.

The difference in length matters for V8's but not here. (the V8 starters for automatics have a longer "snout" and the bendix gear sits out much further than the manual trans starters.)

I have not personally experienced this issue, but I have seen a few RBVs that have it. I think the problem is poorly rebuilt starters, using the wrong bolts for the starter, and not getting it aligned just right. People also try replacing the flexplate/flywheel as well which just throws another variable into the mix... do not replace those unless they are missing teeth, worn out, or otherwise damaged.

I think the safest thing to do is have your original starter rebuilt, make sure the bolt holes do not get egged out, and leave the flywheel or flexplate in place rather than replacing it.

Thanks! My flywheel ring gear teeth were worn badly. I HAD to repalce.
There was no choice. Changing a mounting bolt to stud was also inevitable.