Mark R.

I did an extensive search and read through just about every starter related thread, but didn’t find anything quite like this.

My starter has begun to make a single loud clank each time I start the car (88 S4 5 speed w/~115k miles). It sounds like the starter is not pulling back out of the way quick enough when the engine flares. It is a very disconcerting noise that definitely sounds like metal to metal.

I’m pretty sure it’s the original starter. I removed it, disassembled it, cleaned all the parts real well, reassembled it, and reinstalled it. But that did not help. It is still doing the same thing. While it was apart, I checked the pinion gear and confirmed that it spun freely in both directions (driven and idling).

I pulled the fuel pump fuse so I could crank the engine without it starting. I cycled it numerous times, with different durations, and it never made the odd noise. It cranks very strong and powerful and sounds great.

So the bad noise is definitely linked to the transition when the engine starts and first begins to rev.

I think my next step is to just replace the starter, but I wanted to ask if it could be related to any other area. Could a bad relay or bad ignition switch cause this symptom, and if so, is there some way to test these and rule them out? The starter has never stuck full on. It always retracts, but seemingly just not quite quick enough.

Thanks!

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Mark in Atlanta

87 S4 Grandprixweiss Auto w/LSD (Daily Driver Since 2004).
88 S4 Silbermetallic 5 speed w/LSD (Weekend Driver Since 2003).
84 S Schwarz Auto w/LSD (Sold in 2007 - Daily Driver 1997-2004).
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James Bailey

I think you have diagnosed it correctly....when you pull the starter look at the ring gear just to be sure it is not worn; turn the engine clockwise with the crank bolt...

Mark R.

I do plan to thoroughly visually inspect the ring gear teeth (fingers crossed!).

So what do you suppose is actually causing the metal-to-metal clank?!?

Regardless of what might be causing the delayed disengagement of the starter, isn't the pinion gear designed to able to spin free with the ring gear (to allow for exactly this transitional condition)?

When I had the starter out, I did check to confirm that it was free to spin in the opposite (forward) direction from the driven shaft. But is it possible that it is binding when it is under load....?

Thanks!

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Mark in Atlanta

87 S4 Grandprixweiss Auto w/LSD (Daily Driver Since 2004).
88 S4 Silbermetallic 5 speed w/LSD (Weekend Driver Since 2003).
84 S Schwarz Auto w/LSD (Sold in 2007 - Daily Driver 1997-2004).
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Mark R.

Earlier today, I installed a new starter and it eliminated the problem.

From start to finish, it only took 30 minutes to remove the old starter and install the new starter (from rolling the jack under, to rolling the jack back out).

Nothing quite like a little repetition to make one more proficient at doing something...

I even deployed a new technique with one of my bungees to act as a third hand, by flexing and holding the disconnected metal clutch fluid line out of the way.

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Mark in Atlanta

87 S4 Grandprixweiss Auto w/LSD (Daily Driver Since 2004).
88 S4 Silbermetallic 5 speed w/LSD (Weekend Driver Since 2003).
84 S Schwarz Auto w/LSD (Sold in 2007 - Daily Driver 1997-2004).
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jvandyke

old thread I know but our '87 924s (with an '83 944 engine) has two starters doing the same thing, the "new one" just exploded all the ring and planetary gears, mince meat, why might this be happening do a supposedly reman starter? is it the starter or something on our end? low voltage causing lazy bendix I don't know I'm just don't want to put a new starter on every 3 months. Old starter back on but it makes the same horrible CRACK, hesitates and spins up again, it works, cars starts but I predict this starter will also self destruct very quickly

jeff spahn

You might want to ask the 924 forum. You posted this in the 928 forum.

Wisconsin Joe

928 & 944 starters are not that similar (you say it's a 944 motor). On my 83 944, there really isn't a "bendix" as in a standard starter. That is, there's no "spring loaded extending gear on a screw" type bendix.

The solenoid engages a lever (in addition to being the "big relay" that powers the motor) that pushes the gear out. Then when the solenoid is no longer active, the magnet releases the lever and the gear retracts.

No clue what's going on with yours, but it's not that hard to take it all apart and see what's up.