Can the ring gear hit the starter motor?

[ed_the_robot]

Ok folks, problem!

I fitted a new starter today. Correct type, as far as I know.. New bushing installed after removing all the remnants of the old one with a 12 mm tap as per the wiki page.

She started great, first turn, but there was a metallic knocking that had never been there before. Very slight, but I knew something wasn't right. Engine was immediately turned off.

So, new starter off again and I inspected the ring gear. It looks like the edge of the teeth have caught the pinion of the new starter. The starter pinion also has a very, very slight showing of its contact with the ring gear. This is after 2 starting attempts only.

So how plausible is it for the ring gear to be close enough to the retracted starter pinion? Have I got myself a duff reconditioned hella starter motor from Just Kampers? There is approx a 1mm difference in the pinion position between the new and old units, the recon being slightly longer. This is using the fitting face as the datum.

What should the clearance be when the starter is not engaged?

[kevtherev]

I'm sure there must be a fair few Starter & Alternator refurbishment places in Notts.
I allways take my old starter to them, it sure beats paying for a new one...

If you can hear a noise then it's wrong.
send it back

Have you still got the old one?

[ed_the_robot]

Hi kev, yea I've still got the old one.

I'll ring just kampers on Monday and make sure they know this starter was bad, money back or else!

The slight marking on the ring gear seems consistent with hitting the starter pinion, the pinion just shows incredibly slight evidence of the ring gear hitting it. I'm assuming the ring gear is softer than the pinion in this case, which is odd as I'd have thought it would be the other way around.

Other than the light mark I can see on the ring gear teeth, they look to be in good shape.

Either this starter isn't built with enough tolerance, or my ring gear is sitting to far forwards. The old pinion is worn, so must just clear the ring gear.

I could take a file to the pinion and shave away the area I suspect is touching the ring gear.

Or like you say, ditch it and get my original unit rebuilt!

[Plasticman]

file it and you may invalidate any waranty
sad buying from them anyhow but as its done send it back and get yours refurbed
locasl
mm

[ed_the_robot]

Update on this one..

I tried my blue tac method of testing the clearance to to ring gear.

With a ring of blue tac around the end of the pinion I slid the motor on and then off again.

The test revealed a good amount of clearance between the gears!

I've reassembled everything and tried starting again. This time, no noises, perfect start up and nothing out of the ordinary. Strange, but I'm going to roll with it and keep an ear out!

[kevtherev]

Fitter error..
Just admit your failings and we can move on

[ed_the_robot]

Haha I'll admit it as long as you can keep a secret