I recently replaced my starter in my 92 RS with a 305 TBI and I am having an issue with the new starter. The new starter (premium rebuilt unit from Autozone) will engage the flywheel but doesn't turn the engine over. This is an intermittent problem. At times it will crank right over, but it mostly it just clicks. I added a shim today but I am still having the problem. I have already replaced the new starter once for the same issue. I noticed today that the break light illuminates on the gauge cluster when I turn the key to start even though the parking break is disengaged. I can't say that I have noticed that before. F.Y.I. battery is new and good and I checked the connections, they seem okay. Any help would be much appreciated. Thank you!!!

 

If the pinion does not extend fully, the start solenoid contacts may not be closing, thus the starter motor will not run. Installing shim(s) can sometimes remedy that if the problem is radial clearance. When the starter does operate properly, can you hear any grinding or howling noises from the starter pinion gear? That is often a sign of inadequate clearance.

If there is another problem with the solenoid or bendix, shimming may not help. Were the starter bolts in good condition? If not, the alignment of the starter may be incorrect thereby preventing the solenoid from extending fully.

Of course, it is also possible that the solenoid contacts are defective, or that the cable lead from the solenoid to the starter motor main terminal is loose or faulty.

It is also possible that the starter brushes are not contacting the commutator or that there are other internal start motor problems. If you cannot find a problem with the external connections or the starter alignment it may be worthwhile to exercise the lifetime guaranty and get a replacement, or have your current starter bench tested.