Changed TPS (out of 2 dozen screw drivers, naturally none was the perfect length to get to where they mounted the TPS close to the EGR and the cross-over exhaust manifold) and so far, so good on idle speed.
Now I am back to trying to figure out why after starting sometimes something knocks REALLY badly 2-3 times. Once the engine is at idling speed, all is well, and it doesn't do it every start-maybe 1 out of 5. It'* dramatic enough it sounds and feels like someone is striking the engine block w/ a BIG hammer, and the engine mechanically pulses each instant it knocks (as if it is hanging up on something mechanically for a brief instant).
My feeling was that it was a loose bolt in the bell housing that occasionally flips and gets caught between the torque converter or the flex plate and the housing itself, then flips out of the way again.
Yesterday, the starter quit, giving me the opportunity to examine. Odd that at 60k miles since new, the solenoid quit (no click, but there is voltage at the solenoid terminal, so it'* a dead solenoid for sure).
I dropped the starter, and it looks fine (though obviously I am going to replace it), but I carefully examined with the inspection cover (where you get at the flexplate-to-torque converter bolts), and I can clearly see an area around the T/C shiny steel (outboard of the ring gear teeth) where something has been rubbing, and there are some shallow "dents" as well that I imagine are caused when it "bangs" loudly.
I inspected carefully w/ a flashlight, and probed around w/ a magnet wand, and had someone turn the crankshaft while I looked and probed in the bell housing as well as I could, and I could find absolutely NOTHING down there at the bottom where one would expect to find something loose like that.
Any ideas what it could be causing this, or what could be loose and getting into harm'* way at times?
The rub marks are all around the radius shown with a RED arrow in the photograph that is at this Copy-and-Paste Link: 2013-06-29_0929 - bobinyelm'* library
The narrow rub/scratch mark all around the T/C not that shiny in the photo, and the small shiny indentations are on the other side (but in the same area the arrow points to). They are all in the radius of the T/C right at the arrow-point.
Any ideas or suggestions most welcome as I am sure that at SOME point, whatever it is may do some actual damage to the T/C or something else.
I'm going to post this as a separate thread as well so maybe more folks not following this thread will see it, so if you have ideas, post them here, or there. I'll title the Question "Something loose in my Bell Housing?"