starter disengagement issue

[785sp]

Hello all. I'm having a starter issue I've never encountered on any car.

Recently, I had my clutch replaced and the flywheel removed and polished (of burned material from my long-overdue clutch, so they said). Everything was fine for about three weeks, 500 miles or so. Not sure if what happened next is related:

My starter began making a metallic popping noise just as the engine fired, pretty soft at first, but louder and louder for the nexts ten starts or so. I figured that the solanoid was malfunctioning, ie not retracting fast enough for some reason. Then, the noise got really loud, and the starter stopped working completely.

I replaced the bad starter with a used starter, and the same symptom happened--once again a soft mettalic popping noise. I seem to be headed down the same road, about the destroy another starter in the next ten starts.

I have no clue what could be causing this. Unless I somehow bought a used starter with exactly the same problem as my prior starter developed, maybe the flywheel is the culprit. Could the flywheel somehow be the wrong position (as it was recently removed, cleaned and replaced)?

Also, on the destroyed starter, the very top of the solanoid had cracked, where the larger of the two smaller wires attaches. Something was, and now is, causing it a pretty strong jolt.

Any educated guesses would be highly appreciated.

Dave

[Danglerb]

Last thing fixed, first suspect.

[785sp]

Searching on the internet, I saw a couple of references to my symptom, but with different cars: if the starter is not seated properly against the housing, or if the housing is warped, the "bendix" gear will not allign properly with the flywheel gear and will not retract properly, which can be cured with "shims" between the starter and the housing.

Anyone heard of this happening on a 928?

[Danglerb]

I'd say put it on a lift and see whats going on. As I recall the starter is mounted to a plate that mounts to the bellhousing, and its on the bottom of the car, so maybe it got whacked.

OTOH I don't recall any simple way to adjust the engagement.