Starter Noises on 92 Corvette

[Doutdoor]

One Saturday evening I went into my garage to start the car and click-click-click and then it started but the starter motor kept running. I turned the motor off but the starter kept running so I flipped the key back on to turn the engine back on. Then I disconnected the negative battery terminal to turn everything off. The next day I called around and got a price on a rebuilt starter from Autozone. Took the old original starter out and installed the rebuilt one. When starting the engine, it sounded terrible. Kind of like a grindy, it's not properly engaging type of sound. I checked the rebuilt starter with the old one before I installed it and they looked identical. Anyway, I figured that I probably should not have bought a rebuilt unit, so I just bought a brand new Hitachi high torque permanent magnet starter for Chevrolet applications with 153 or 168 tooth flywheels. I asked the guy before I bought it if it would work in a 92 Corvette and he said yes (as I have no idea how many teeth on the flywheel in the car). I installed the Hitachi starter but it sounds worse than the rebuilt one I just removed.

Is there a chance the teeth on the flywheel are tweaked because of the problem with the original starter. Or, am I just running into bad luck with these starters? I did look at the teeth on the flywheel through the opening in the cover pan on the botom of the transmission and they looked ok. I didn't take the cover off though to inspect the entire flywheel and I suspect I'll probably have to do this. Any help would be appreciated. I've never had a problem like this with a starter.

Thanks,
Dave

 

[WhalePirot]

Might be a control problem, prior to the starter. The original starter did not disengage. Do the new ones? You must have new solenoids, at least with the mini unit. I initially thought the solenoid was the problem, but if the new Hitachi was not disengaging either, something is still telling it to stay engaged.

I'd check for voltage at the small terminal on the solenoid with a key start, but released. It may be better to try this with the starter out of the car, but connected.

Then I'd manually jump the solenoid and see if the gear is binding (improper alignment or spacer) and that is not allowing the disengagement, or if it is an electrical issue.

 

[redc4corvette]

I would not engauge that high torque starter on the garage floor unless you want to chase it to your nabors house.
I would take a round feeler gauge cheap at the auto store,see if you have 0.05 clearence between the flywheel and starter grar inside between the teeth.
I think you have a 168 tooth flywheel.

 

[I_R_DA_ONE]

It sounds like you have an alignment problem between the ring gear or flywheel and the starter....loosen your starter just enough that you can move it , then push the front [the end near the front of the car] tward the motor... It doesn't have to be off much to cause what you are experincing...

I hope this works

Mike

 

[bill5674]

sounds like you need to shim the starter. you can get them at any parts house.no need to remove starter just loosen the bolts and slip acouple shims in place.that should help

 

[Doutdoor]

Thanks everyone for the advice. The Hitachi starter did come with a couple of shims so I'll try that and see if it works. I was also going to remove the pan that houses the flywheel and torque converter and check the alignment visually between the starter and flywheel. I just hope the teeth on starter pinion didn't get messed up.

sounds like you need to shim the starter. you can get them at any parts house.no need to remove starter just loosen the bolts and slip acouple shims in place.that should help

 

[WhalePirot]

I would not engauge that high torque starter on the garage floor unless you want to chase it to your nabors house.

That there's, funny.

I've done this a number of times and hardly know MY neighbors.

 

[Doutdoor]

I pulled the torque converter housing. With the new starter bolted up I have more than twice as much clearance from the pinion gear to the flywheel teeth(about 1/4" or .250 in.) as what the instructions say I should (.100 in +/- .40). Something is not right. The starter does not engage properly when starting the engine. The flywheel looks good. Moving the starter closer to the flywheel would entail having to slot the mounting holes which I don't think is a good thing to do. Also, the torque converter housing would have to be notched. I talked to the guy I bought the starter from and he says the Chevy small block application is right and it it should work without any problems. I've run out of ideas.

Thanks

 

[bill5674]

only thing comes to mind is make sure the pinion gear has the same number of teeth as the one you took out.If you can talk to someone at another supply house.sometimes folks don`t like to 'fess up to a mistake

 

[Doutdoor]

only thing comes to mind is make sure the pinion gear has the same number of teeth as the one you took out.If you can talk to someone at another supply house.sometimes folks don`t like to 'fess up to a mistake

Bill, I did notice before I first installed the starter that it only had 10 teeth. The stock OE starter's have 11. As it turns out, I called Hitachi's Aftermarket Sales & Technical Service office today and spoke to one of their techs. He told me the starter I purchased was not made to work on Corvette's (even though the application says all small & big block Chevy's). The guy I bought it from says he'll give me a full refund, so at least I can get my money back and then buy new Denso starter made specifically for 92-96 Corvette's.

Thanks,
Dave

 

[Doutdoor]

Just as a follow up to this Thread, I wanted to let everyone know the outcome of my starter issue. I wound up buying a new PowerMaster starter. After doing more research, I decided it was the best starter for the money. The Powermaster starter is a high torque gear reduction starter that puts out 200 ft./pound of torque. More than enough torque for any of our hiigh compression engines. I verified the correct application directly with Powermaster as part # 9502 for 92-96 corvettes with the LT1 engine & 153 tooth flywheels. The starter cranks the engine over in a heartbeat. I paid $189 + shipping so about the same price as a new Denso starter. It weighs only 8 lbs. The PowerMaster starter even comes with it's own dyno sheet to show you how it "tested-out" on the bench. All in all a real "live n learn" lesson for me to only go for the best when installing a replacement part on the vette.

Thanks,
David Denning
East Bay, Ca