How change replace starter gear pinion on countax c800

flywheel teeth get damaged in 3 places for 6 cyl or 4 for v8 If the teeth are damaged then the fix is a replacement ring gear
now if the car is automatic it will not have a flywheel as the torque convertor does that job
there is a flex plate bolted instead to the crank shaft and inturn bolted to the torque converter
They are kown to develope faults and crack off at the crank shaft so that they become warped ( not allowing full pinion engagement) or dreak off altogether and not turn the crank at all
The thrust bearings on the crank generally do not fail as they run in oil all the time so disregard that suggestion( if the thrust bearing was to fall ot completely , the added movement is 1/8 " and the pinion would still engage a good ring gear)
Now the teeth have to be replaced so for an automatic it is a new flex plate ( box out )
for a manual it is flywheel off and a new ring gear fitted to the flywheel ( box out )
check the pitch of the teeth of the new starter
the movement of the pinion can be checked by an accredited auto electrician and adjusted by the encentric pivot pin in the solenoid fork
So what ever happens the box has to come out for the repair

Sure, if it fits. The new starter pinion has to have the same tooth pitch (spacing) as the flywheel ring gear. You can check this by comparison with the old starter.

It also has to have the same flange diameter as the old one, and the same securing bolt centre distance.

Both starters are 12V and that's the only other thing that matters.
.

-you mean broken teeth...? If so possibly crank the engine while it's still running.


Good Luck


Mai

You may need to add shims to increase pinion gear to ring gear clearance !
Inspect the flywheel ring gear for damage or unusual wear.

?€¢
Shim the starter if applicable.

?€¢
In order to add pinion to ring gear clearance a full size shim must be used. Do not shim only 1 starter mounting bolt. There are 3 shims available in different shapes (for clearance). All are 1 mm (0.039 in) thick.

When you took off the old starter did you see any thin strips of metal ?

If you had a flywheel replaced it is possible that it is not reinstalled properly. Check for engine vibration at idle . Check that the starter is in correctly. IT appears that the starter pinion is not meshing correctly with the ring gear and that is your noise . It goes after starting because the pinion disengages from the ring gear. The problem is a misalignment between the pin ion and the flywheel ring gear ( nothing at all about polished gears ). IT is all in the installation of the flywheel -starter and gear box.

the ring gear on the fly wheel may have damaged teeth or not have the right gear teeth count to be compatible . Pinion teeth have to match the ring gear teeth or they have trouble meshing and that makes it hard to turn over. If the ring gear teeth have been damaged then the gear box will have to come out to get the fly wheel / flex plate off. If it is auto then it is a simple matter of replacing the flex plate . But if manual the ring gear is removed from the flywheel and a new one fitted. Most accredited service shops can do this operation. count the number of teeth on the ring gear and the number on the starter pinion and take the figures to an auto electrician and he will know it they are right.

There is no way the ring gear will hit the starter pinion unless the fly wheel bolts on the crank shaft or loose allowing the flywheel to run out of true. If you have had clutch/ rear seal work done lately the fly wheel will only fit in one position and if that was ignored at some time then the fly wheel will run out and touch the starter pinion.. I would also check the adjustment on the starter pinion as it has to be set by the lever pivot to a correct distance or it will touch the teeth of the ring gear

Inspect/Test/Service/Replace

• If your testing indicates that the starter must be removed, the first step is to disconnect the negative cable at the battery.
• It may be necessary to place the vehicle on a lift to gain access to the starter. Before lifting the vehicle, disconnect all wires, fasteners, and so on that can be reached from under the hood.
• Disconnect the wires leading to the solenoid terminals.
• To avoid confusion when reinstalling the starter, it is wise to mark the wires so they can be reinstalled on their correct terminals.
• On some vehicles you may need to disconnect the exhaust system to be able to remove the starter.
• Loosen the starter mounting bolts and remove all but one.
• Support the starter while removing the remaining bolt.
• Then pull the starter out and away from the flywheel.
• Once the starter is free, remove the last bolt and the starter.
• Once the starter is out, inspect the starter drive pinion gear and the flywheel ring gear.

Starter drive and flywheel ring gear wear patterns. Courtesy of Ford Motor Company.

• When the teeth of the starter drive are abnormally worn, make sure you inspect the entire circumference of the flywheel.
• If the starter drive or the flywheel ring gear show signs of wear or damage, they must be replaced.
• Reverse the procedure to install the starter.
• Make sure all electrical connections are tight.
• If you are installing a new or remanufactured starter, sand away the paint at the mounting point before installing it. Also, make sure you have a good hold on the starter while installing it.
• Many General Motors' starters use shims between the starter and the mounting pad.

Shimming the starter to obtain proper pinion-to-ring gear clearance. Courtesy of General Motors Corporation - Service Operation.

• To check this clearance, install the starter and insert a flat blade screwdriver into the access slot on the side of the drive housing. Pry the drive pinion gear into the engaged position.
• Use a wire feeler gauge or a piece of 0.020-inch (0.5080-mm) diameter wire to check the clearance between the gears.

Checking the clearance between the pinion gear and the ring gear.

• If the clearance between the two gears is incorrect, shims will need to be added or subtracted to bring the clearance within specs.
• If the clearance is excessive, the starter will produce a high-pitched whine while it is cranking the engine.
• If the clearance is too small, the starter will make a high-pitched whine after the engine starts and the ignition switch is returned to the RUN position.
• Every starter should be bench tested after it is removed and before it is installed. to conduct a free speed or load test on a starter, see the free speed test.

Inspect/Test/Service/Replace

• If your testing indicates that the starter must be removed, the first step is to disconnect the negative cable at the battery.
• It may be necessary to place the vehicle on a lift to gain access to the starter. Before lifting the vehicle, disconnect all wires, fasteners, and so on that can be reached from under the hood.
• Disconnect the wires leading to the solenoid terminals.
• To avoid confusion when reinstalling the starter, it is wise to mark the wires so they can be reinstalled on their correct terminals.
• On some vehicles you may need to disconnect the exhaust system to be able to remove the starter.
• Loosen the starter mounting bolts and remove all but one.
• Support the starter while removing the remaining bolt.
• Then pull the starter out and away from the flywheel.
• Once the starter is free, remove the last bolt and the starter.
• Once the starter is out, inspect the starter drive pinion gear and the flywheel ring gear.

Starter drive and flywheel ring gear wear patterns. Courtesy of Ford Motor Company.

• When the teeth of the starter drive are abnormally worn, make sure you inspect the entire circumference of the flywheel.
• If the starter drive or the flywheel ring gear show signs of wear or damage, they must be replaced.
• Reverse the procedure to install the starter.
• Make sure all electrical connections are tight.
• If you are installing a new or remanufactured starter, sand away the paint at the mounting point before installing it. Also, make sure you have a good hold on the starter while installing it.
• Many General Motors' starters use shims between the starter and the mounting pad.

Shimming the starter to obtain proper pinion-to-ring gear clearance. Courtesy of General Motors Corporation - Service Operation.

• To check this clearance, install the starter and insert a flat blade screwdriver into the access slot on the side of the drive housing. Pry the drive pinion gear into the engaged position.
• Use a wire feeler gauge or a piece of 0.020-inch (0.5080-mm) diameter wire to check the clearance between the gears.

Checking the clearance between the pinion gear and the ring gear.

• If the clearance between the two gears is incorrect, shims will need to be added or subtracted to bring the clearance within specs.
• If the clearance is excessive, the starter will produce a high-pitched whine while it is cranking the engine.
• If the clearance is too small, the starter will make a high-pitched whine after the engine starts and the ignition switch is returned to the RUN position.
• Every starter should be bench tested after it is removed and before it is installed. to conduct a free speed or load test on a starter, see the free speed test

• If your testing indicates that the starter must be removed, the first step is to disconnect the negative cable at the battery.
• It may be necessary to place the vehicle on a lift to gain access to the starter. Before lifting the vehicle, disconnect all wires, fasteners, and so on that can be reached from under the hood.
• Disconnect the wires leading to the solenoid terminals.
• To avoid confusion when reinstalling the starter, it is wise to mark the wires so they can be reinstalled on their correct terminals.
• On some vehicles you may need to disconnect the exhaust system to be able to remove the starter.
• Loosen the starter mounting bolts and remove all but one.
• Support the starter while removing the remaining bolt.
• Then pull the starter out and away from the flywheel.
• Once the starter is free, remove the last bolt and the starter.
• Once the starter is out, inspect the starter drive pinion gear and the flywheel ring gear.

Starter drive and flywheel ring gear wear patterns. Courtesy of Ford Motor Company.

• When the teeth of the starter drive are abnormally worn, make sure you inspect the entire circumference of the flywheel.
• If the starter drive or the flywheel ring gear show signs of wear or damage, they must be replaced.
• Reverse the procedure to install the starter.
• Make sure all electrical connections are tight.
• If you are installing a new or remanufactured starter, sand away the paint at the mounting point before installing it. Also, make sure you have a good hold on the starter while installing it.
• Many General Motors' starters use shims between the starter and the mounting pad.

Shimming the starter to obtain proper pinion-to-ring gear clearance. Courtesy of General Motors Corporation - Service Operation.

• To check this clearance, install the starter and insert a flat blade screwdriver into the access slot on the side of the drive housing. Pry the drive pinion gear into the engaged position.
• Use a wire feeler gauge or a piece of 0.020-inch (0.5080-mm) diameter wire to check the clearance between the gears.

Checking the clearance between the pinion gear and the ring gear.

• If the clearance between the two gears is incorrect, shims will need to be added or subtracted to bring the clearance within specs.
• If the clearance is excessive, the starter will produce a high-pitched whine while it is cranking the engine.
• If the clearance is too small, the starter will make a high-pitched whine after the engine starts and the ignition switch is returned to the RUN position.
• Every starter should be bench tested after it is removed and before it is installed. to conduct a free speed or load test on a starter, see the free speed test.