Help with starter issues ?
 

I have had an 'intermittent' start issue . 3 days ago after fixing the wipers (adventures in wiper transmission removal and replacement..)

Details:
I would get in the car, turn the key. NO start. No crank, no click.
Replaced the '53' relays. Tapping the starter solenoid (sounded crazy to me but i tried it..) would work but it would be 'tap..tap..tap..bang..tap..' Eventual start.

Tapping is not desirable and impractical when dressed nice and its raining, so I tried to fix this.

Remove the starter, removed the solenoid. Took the chance to install my Jagermount (that was sitting in the hatch for over a month..)
WD 40 down the screw holes on the solenoid, Heavy grease on the plunger (There was grease there already, so I cleaned and freshed the grease.)

Replaced the solenoid, re-installed the starter. Now the starter spins but not engaging the flywheel. ALso, There seems to be a 'crack' or gap on the rear behind the starter area. (my brother says it was not 'new' as it was filled with what appears to be years of dust/grease/fluff/smegma..).

My mechanic consultant 944/951 guru (But knows next to nothing about 928s) said from the start that I needed a new starter, and recommended Autohe77, however I appear to have a genuine Bosch and would like to think that if its spinning, maybe there is something I did wrong, or something else that is unusual.

Two fold question (sorry taking so long to get to point..).

1- Is there usually some sort of inspection gap or area between the rear of the starter. I can literally look in and see where my flywheel is. It appears to be a 1 cm gap.

2- Starter spinning but not engaging. The starter seems to go only one way. Is there something wrong here? or am I going to have to bite the reman parts bullet.?

Thanks in advance, (for your help and guidance).

The starter may spin, but it may not be able to project the drive unit to the teeth of the flywheel. Sounds like it's jacked up inside.

when the sol is energized, the magnet pulls the plunger into the large contacts that make the connection to turn over the starter. At the same time the sol pulls the forks which move the bendex into place. So 2 things could not be happening. Either your bendix (clutched gear) is not moving due to you didn't get the forks in the right place, or the clutch part of the gear is slipping.

Is it getting power?
You have a starter relay to contend with in the panel.
Also the solenoid wiring passes through the 14 pin connector.

Yes its my solenoid. But, I took it all apart and when I reinstalled I get spin but no engagement. I think I reinstalled the solenoid incorrectly..
I will try again, and also will be getting working starter ... Thanks guys.

What year car?

Are you referring to the gap between the starter/mounting bracket and the lower bell housing cover? IIRC there is supposed to be a sealing piece between there, I order one but didn't install it, ended up being a piece of foam with an adhesive backing. Otherwise that gap should be normal.

Thanks everyone.

A local guy had a starter, that fixed the start problem.

Threw a Jager speed mount in also to get the motor in the proper position until I can do steering rack/motor mounts. All fixed for now..