Originally Posted by Tech II
You will have to remove the inspection cover, and manually rotate the engine, and look for damaged teeth on the flexplate......could also have a damaged pinion on the starter drive...also make sure the starter is aligned correctly(you tightened the two bolts evenly, no dirt on mounting surfaces)... don't usually use spacer plates on these starters....if flexplate is ok, may need another starter.....
I will have to see if I can get it on a hoist today if we have enough time but I did notice when the new starter went in the very edge of the flexplate looked like the teeth were just barely nicked... like the corner of 3 teeth were kinda filed off.
I dont see how I could have damaged the pinion unless its by operating the starter with a bad flexplate. In general its a noisy starter... but seems like there is a spot that it makes more noise then normal. I will stick a prybar into the flex plate and rotate to see if I can find a problem.