Starter Grinding, but Still Starting

[LoganP]

I've got a '99 Ranger 4.0 5speed. The truck runs fine, but doesn't start cleanly. The engine has no problem starting, but I can hear grinding, I think from the starter. For some context, this was originally an automatic that was manual swapped at some point in its life by a previous owner. So far I've replaced the flywheel, clutch, slave cylinder, starter, starter wires and relay, and battery. Most of these needed to be replaced anyways, but the grinding started before I replaced everything. The previous flywheel teeth were worn down to the point the starter would free spin. I think the starter misaligned originally because the bellhousing was missing 3 of the top bolts. When I first started the truck after replacing the flywheel and starter, it started smoothly, but then later starter grinding again. Any troubleshooting to fix the grinding would be helpful.

 

[Uncle Gump]

I think there is a slight difference in the engine plates between auto and manual.

 

[LoganP]

What part do you mean exactly? And how would I fix it?

 

[Uncle Gump]

The separator plate between the engine and transmission. It's serviceable by dropping the trans.

 

[LoganP]

The plate that's on there is the one that was there when I got the truck, when it was already swapped to manual. Is there any reason it would suddenly change? When I first reassembled everything it worked fine for a little while.

 

[alwaysFlOoReD]

It could be the starter nose. Iirc there is a difference between auto and manual. And you bought a "new" one... It may have been in the wrong box.

 

[Uncle Gump]

Well... you did say it wore the teeth out. So something was wrong to begin with.

That plate puts the starter where it needs to be.

 

[LoganP]

How can I make sure it's the right plate? I have no problem getting it out if I have to. It seems to be the manual spacer, as it has the mounting point for the starter in the right spot and of the right size. I ordered my starter from napa and it looks identical to the old one and says its for the manual trans. Based on pictures online it appears to be the right one. My next step before ordering anything is reseating the spacer to make sure it is sitting perfecly.

 

[lil_Blue_Ford]

How can I make sure it's the right plate? I have no problem getting it out if I have to. It seems to be the manual spacer, as it has the mounting point for the starter in the right spot and of the right size. I ordered my starter from napa and it looks identical to the old one and says its for the manual trans. Based on pictures online it appears to be the right one. My next step before ordering anything is reseating the spacer to make sure it is sitting perfecly.

I want to say that most of the plates I’ve come across are stamped… I have a couple out, I’ll go check and see…

 

[LoganP]

https://imgur.com/a/wGazU8Q

Just unbolted the starter to examine the spacer plate. Could this about of bend in the plate be the issue? Gonna try to straighten it out

 

[LoganP]

Just tried bolting in the starter with 2 clamps holding down the lifted section of the plate. No change to the start sound, however I noticed it's mostly audible in the latter half of the start, I think when the engine is actually starting to turn itself. Unfortunately I don't have time tonight to remove the plate completely

 

[alwaysFlOoReD]

I don't think its the bend in the plate.

 

[RobbieD]

One more thing to consider, or check: were the large hollow dowels in place, at 3 and 9 o'clock, when you last put the engine and trans back together?

Two of the bellhousing bolts go through these hollow dowels, and they are what actually aligns the engine and trans properly to each other.

 

[LoganP]

Yes they were in place. Tomorrow I'm gonna unbolt the trans and make sure the entire spacer plate is in the right spot and not bent up, just to be sure that's not the issue. I don't think the engine and trans are unaligned as the truck drives great.

 

[alwaysFlOoReD]

Yes they were in place. Tomorrow I'm gonna unbolt the trans and make sure the entire spacer plate is in the right spot and not bent up, just to be sure that's not the issue. I don't think the engine and trans are unaligned as the truck drives great.

Make sure you remember to look for the stamping; manual or automatic. I know the 2.9 spacer plates are stamped.