[chasracer]

The chrome piece is just stuck - probably catching the underside of the brush holders. And the problem you describe if usually one or more of the brushes are stuck and not touching the commutator. I just repaired one of my mini starters the other week with the same exact problem. Moisture had gotten into it and two of the brushes were stuck and not touching. Solid klunk everytime I hit the starter button.

 

[chasracer]

but that's not what the OP, Fang16 is describing, from his first post...



Solenoid or wiring/switches problem. Not the starter motor itself.

The klunk noise on mine was the Ford solenoid I have it wired through. With the starter out and on the bench, connecting 12v to it, there was nothing. My response should have been clearer. What I found was 2 of the 4 brushes were stuck, once I cleaned everything up the motor worked fine. The pic is a replacement assembly I was looking at.