Tampa 928s

78 Euro 5-Speed

I am getting a grinding noise as soon as the car starts and there were visible nicks on the ring gear. I substituted a new starter so this is not the problem. Any one had a similar situation and if so did shims help or am I stuck with the old 78 pack.

Notes:
Changed from a 78 to an 82 clutch pack and problem started. I did not read anything that indicates that this would not be compatible as the newer parts are listed in the manual and can be used as replacments.

The 78 ring gear was attached by bolts from the back to the flywheel, the intermediate ring is bolted to the ring gear. The 82 has the ring gear attached via rivets to the intermediate plate. Either case the ring gear is flat against the flywheel.

Feedback Thanks

Mrmerlin

pictures of what your doing would greatly assist in a proper diagnosis.

Tampa 928s

Trying to post pictures via the IPad and never can get it to work correctly The links below should work The only picture that I believe would help is of the the slightly damaged ring gear.

The test starter is used so there is a chance it could have a problem but it came from a working car and same noise.

https://photos.google.com/share/AF1Q...VpQl82cEZjVDln

https://photos.google.com/share/AF1Q...VpQl82cEZjVDln

Tampa 928s

Pictures before removal notice ring gear attachment bolts.

https://photos.google.com/share/AF1Q...1iVGw2cjRQcFRR

https://photos.google.com/share/AF1Q...1iVGw2cjRQcFRR

Mrmerlin

Does the ring gear rub the starter if you turn the engine over by hand.
I think your going to have to take pictures of both of the assemblies on the bench ,side by side.

toofast928

Tampa your using the OE Bosch starter right? There was fitting problems with the Hi-Torque starter.

Tampa 928s

Both are factory starters.

This is a pain it has headers and to remove anything it is a major project. I had both the 78 and 82 on the bench and did a side by side visual before it went in. Maybe should have taken measurements but ring gear reguardless of attachment still sits flat on the flywheel. I hate to buy a new starter just to test 2 bad starters so I need to do a little more testing on the pinion operation.
Is there any specs on the gear travel?

Tampa 928s

To answer your ? MrM the starter does not rub on the ring gear when turned by hand.

This is what I found the replacement starter "used" the pinion gear is hanging up when power is removed, the original starter is slow to retract. I have not tested a starter in years but believe the gear should snap back when power is released. I am getting to believe that a new starter is in my future.

https://goo.gl/photos/DoBBXJkUPX6MMHmW9

Mrmerlin

well a starter isnt rocket science, put it on the workbench and take it apart,
you will see how it works,
NOTE type into you tube how to rebuild a Bosch starter,
its pretty easy
remove any old grease and add some fresh,
make sure the solenoid internals are free to move and the spring is in good condition

Tampa 928s

I agree, I did take it apart "original starter" and it seems to be in pretty good shape but spring seems weak did a little cleaning. The loaner starter is just that a loaner and if I take it apart it becomes mine so for $138 a new one seems to be a easy solution. I just hope this is the issue but after looking at some videos the gear retracts hard and fast unlike both ones I have, age and usage may have caught up with them.