Starter grinding, 4.0 SOHC. HELP!

[ftlbs]

Back in February, I bought a 2003 Ranger FX4 Level II as a project for my 15yo son. Right away, we noticed the starter motor was grinding. We replaced the starter, but noticed that the flywheel teeth were damaged and the starter still grinds.

Fast-forward 9-months: We just reinstalled the engine after machining and completely rebuilding it. We also had the transmission and transfer case rebuilt and installed a brand new flywheel, clutch, and another new starter. Last week, we started the fresh engine for the first time. The engine fired right up and sounds AMAZING. But… the starter motor still grinds when cranking. What the heck??!! Flywheel, bellhousing, and starter were all torqued properly.

Banging my head and looking for some help. Any thoughts or ideas??

NOTES:
2003 Ford Ranger FX4 Level II
4.0L V6 SOHC
5-Speed Manual Transmission

 

[franklin2]

You did install the thin plate between the engine and the transmission? If the plate is there, if you loosen the starter a little bit, can you move it a little bit? Is the hole in the plate worn out? The hole in the plate is what positions the starter.

 

[ftlbs]

You did install the thin plate between the engine and the transmission? If the plate is there, if you loosen the starter a little bit, can you move it a little bit? Is the hole in the plate worn out? The hole in the plate is what positions the starter.

Yes. The spacer plate is installed. I think the starter fit pretty well, but I will have to loosen the bolts and see if there is any play.

 

[ftlbs]

Loosened the bolts on the starter motor and there is very little play (maybe 1/16”). The spacer plate seemed in decent condition when we installed it, but we’re tempted to drop the spacer plate to inspect it more thoroughly. If needed, where could find a replacement spacer plate??

 

[mikkelstuff]

What about the starter drive? How old is that starter? They don't last forever.

 

[ftlbs]

What about the starter drive? How old is that starter? They don't last forever.

Starter and Flywheel are brand new. Well…technically the starter is a reman.

 

[ftlbs]

Pulled the spacer plate out today. The two holes for the dowels have been cut out which could certainly lead to a misaligned starter motor. I straightened out a few small bends in the plate and will reinstall. I should be able to hold the plate in the correct location when tightening the bell housing. I will report back.

 

[franklin2]

Good find. Hopefully the bellhousing pinches the plate good enough to hold it in position.

 

[ftlbs]

I’m pleased to report that we got it back together today and the starter is no longer grinding.

Lessons learned:
- The thin spacer plate had a few small bends in it that we straightened. Also, I worry about those alignment holes that have been cut out for the dowels. Need to keep an eye on that.
- The solenoid on top of the starter motor can interfere with the engine block if the starter is not perfectly straight when installing. It is wise to take care when installing the starter motor so it’s not crooked. If bolts are tightened, and the starter motor is crooked, the spacer plate can get bent and the starter gear will not line up with the flywheel