i'm at the end of my t56 swap into my 89 ta i have a CSI mini starter due to my hooker long tubes. before the swap i had to play with shims to get it just right but was able to get the starter to work. After the swap i'm stuck starter makes a banging noise and does not turn motor over

i tried the following scenarios

-all the shims
pulled spark plugs out
-a washer + shims
-2 washers + shims
no shims forced the starter gear out and mated to flywheel and rolled motor over by hand gear seems to mesh just fine with flywheel teeth.

 

Could it be the starter is damaged internally?

 

possible, starter maybe has 3000 miles the car has been out of service for a few years looks new on the outside. I'll look around and see if there is a way i can test that

 

Take the starter out, put it in a vice then hook a battery up to it with jumper cables like this, hook positive up to the terminal that has the nut on the starter on the solenoid that your battery cable goes to then hook your negitive side onto one of the ears on the starter mounting surface and hook the battery up. then get a piece of wire and hold the wire on the positive terminal and then hold it on the solenoid ignition wire and see if it pops out and spins.

 

if i test out of the car do i need to simulate a load to accurately test my starter?
tonight i'm going to have someone crank it over so i can watch to see what is going on.

 

i had my wife turn the car over it appears that the starter hits the fly wheel shifts the flywheel back and then makes the loud noise. (is it possible the clutch assembly is hitting somewhere and preventing turn over?)

i was thinking the something in the drive line was binding so i jacked the rear of the car of the ground put the car in gear and rotated the crank manually thinking it was binding somewhere. but i can turn the rear wheels i tried a couple gears with no issue. (keep in mind no spark plugs)

I was also reading that bent starter mounting bolts can change starter angle causing issues i checked mine they are straight.

 

today i took the starter out cleaned all the connections, took the starter a part and made sure there was no indications of internal damage. extended the pinion and made sure it lined up with the ring gear on the fly wheel turned the key and it made the same noise.

Im still lost i'm to the point now where i'm going to have rebuild the starter

any suggestions?

 

bump

 

does it appear that i have clearance issues? also you can see the wear on the pinion the gear does extend further i just could not hold the camera and the pliers when i took all the photos

 

the starter gear has some damage. on the side that engages the flywheel first, the starter gear teeth should be beveled so it can slid into the flywheel teeth.
that damage could easily prevent the starter from engaing the flywheel.
you can see the bevel in these pics.

 

they didn't attach the first time,..

 

i extended the bendex so it was meshed with the flywheel and still won't turn it over so i'm convinced its a starter issue. Monday i'm taking it to a place that deals only in automotive electric components to get their take on the issue. thanks for the photos DENN_SHAH i'll report what i find

 

thanks for all the help guys, i got word from the electrical shop i took my starter to. They stated nothing is wrong with the starter i had them replace the gear, put the starter in shimmed it, hooked the battery up and jumped the terminals with a screw driver it meshed and turned the motor with no issue.

i put the transmission back in jumped the terminals still working

hooked up the drive shaft all the exhaust and tried to turn the motor over with the key noise is back.

i jacked up the rear wheels and jumped the starter turns over just fine again.

i held the safty switch in turned the key and the motor rolled over.

i adjusted the travel on the slave cylinder and tried the pedal and the key and it rolled over just fine.

so atlease i have a new starter gear and practice installing my tranny

thanks guys for all your help