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[Damn it ^^^]

This is something i've never seen before. 5 days ago I tried to start the car and it locked up solid. Never had a problem with starting before that.
 Next day I got a new starter motor but when I removed the old one I got a shock:

The casting on the end of the starter had been smashed off by the flywheel/ring-gear. The shaft inside the starter was a bit wobbly as expected but the teeth looked fine. This was the original starter motor, 11 years old and 73000 miles. All the broken pieces of casing were still inside the bell-housing and I didn't fancy dropping the gearbox so I found a rubber plug at the bottom of the bell-housing

and when I stuck my finger in there I found all the broken bits!

[Damn it ^^^]

Anyway, after I got all the bits out, I fitted the new starter and everything was great
I did 600 miles in it, lots of start-ups, no problems. Then today it turned over and then "clunk" - locked up again! (Thats 2 AA callouts used up this week) took ther starter off and :



-thats my starter new starter after 600 miles 

Has anybody else had this happen? Any idea what's biting the end off my starter motors or why?  :-?

[al brown]

Never seen it that bad but check for stones in the bellhousing or missing teeth on ring gear. Least posible option is cracked bell housing causing started to flex, VERY doubtfull, but check anyway.
Al

[Damn it ^^^]

Thanks for the reply Al.
I think the bellhousing is sound, no damage I can see there, both starters were a good, tight fit and bolts were still tight when I removed them.
The teeth on the ring-gear felt ok all the way round as I rotated the engine before fitting the new starter and I dont think it's moved on the flywheel either. Rubber bung was in place in the bellhousing too so I dont think any stones or other nasties could have got in there.
I think I need the gearbox off to have a good look now.

[Kevin Wood]

I'd say foreign object in the bellhousing is a possibility, although I'd expect you would hear it rattling around when the engine's running too.

Other option is that, for some reason, the pinion is being positioned too close to the ring gear and it's straining the mounting of the nose bearing.

Does the starter locate firmly in position on the engine or can it be moved once in position? Not sure if the front of the starter locates in a recess in the block itself or if it's into a shield plate. If it's the latter is the plate in position? Any sign that it has shifted or got bent?

Kevin

[unlucky alf]

did you check that the ring gear is running straight, also has the tin bit fractured or bent?, it all seems to point to the ring gear

[semisheen]

Could it be somthing thats broke off the pressure plate their isnt really anything else in there ...wich eaver way you look at it i think you may have to split the eingine & box to get to the bottom of that 1 

[semisheen]

Just noticed its a auto  ...ignore my last post

[Damn it ^^^]

Thanks for all your suggestions.
Yes the starter does locate nicely into a recess in the bellhousing - about 7 or 8mm and it's a snug fit so no way it can move anywhere once its in, and it was still bolted in tight.
I've re-checked the ring-gear teeth all the way round and the ring-gear appears to still be located perfectly and running true on the flywheel. But I'll be able to see more later on when the autobox is off. I'll update later on if and when I find the problem.

[Marks DTM Calib]

Any fore/aft play in the crank?

Should be easy to check at the aux pulley end.

[Damn it ^^^]

Never thought of that Mark.
But I've checked now and theres no movement at all and the rear crank seal looks ok too, no leaks.
I've had the autobox out, torque converter off, flywheel/ring-gear/tin plate thing out and all seems fine. There were a few marks on ring-gear but nothing serious so it's all going back together. I've spun it over with the starter in and autobox off so I can see whats happening and the starter engages and runs perfectly on the ring-gear. (I took the starter motor back to the shop and told them it must've had a fault in the casting! they apologised for the hassle and gave me a replacement )
So it's almost back together now, fingers crossed this time!