I have a fairly new 496 that I installed a mini high torque starter that will sometimes crank the car perfect, but sometimes it just made a clanking noise. So, I crawled under the car and watched it as I had someone turn it over. Cause I thought it might have had a bad solenoid, but the starter is fine what's happening is sometimes when the starter teeth go to make contact with the flywheel the teeth actually hit the flywheel teeth square on. Basically two teeth on the starter gear hit the backside of two teeth on the flywheel. But when it actually lines up it fits the groove like a glove and turns over great. Sometimes I have to crawl under the car an spin the gear a little to catch the grove once it starts hitting. I've tried shimming it from one extreme to the other. It's a 168 tooth flywheel and the starter is supposed to be ok with it. I really shouldn't need to shim it anyway. Its my first time seeing one mesh up perfect sometimes and other times it won't mesh up at all. Any suggestions?
I wonder if the gear is to close to the flywheel and doesn't have enough room to spin and catch the teeth at times because it basically shoots straight out and then hits the flywheel. I'll measure it tomorrow. The groove clearance is good (Teeth to Teeth), but I'm not sure about the gear to flywheel distance. If I had to guess I would say 1/4 of an inch. Thanks in advance for the replies!