I am haveing serious problems with my starter and flywheel on my 1983 Full Size Ford Bronco. The problem is simple enough, but perplexing. The starter is the correct one for a 351W Automatic. When i install it it works well for about a week, then the teeth do not line up with the flywheel and I get the bad grinding sound of the teeth not conecting. The bolt holes on the starter have about 3mm of play, so when I unbolt the starter and rebolt it (using a pry bar to push it as far over as I can) the starter works again for about another week. I have shimmed the starter, tried locking the starter in the place (shifted 3mm as far over as it can go) and have done everything short of replacing the flywheel. There are no teeth missing or worn on the flywheel (I have checked each one!) and the starter is brand new (the third one I have tried). HELP! I have no idea what to do and I do not want to replace the flywheel if this is not going to fix the problem. Auto Zone sells two different flywheels for the original 302 and the 351W. They can not tell me the difference though. Has anyone out there seen this before? PLEASE HELP! Thanks! Discouraged Bronco Owner...

 

Well mate what I would do is this:

You said that there was 3mm give? I assume that is 3mm altogether (1.5mm either side of the bolts that hold the starter on) Well I'd make a sleve for the part of the bolt which goes into the casing of the starter. You can do this with a small piece of metal pipe or if the sleeve needs to be thicker on one side, pack it up with metal. Better still, if you are handy with a welder, fill the hole in the starter up and re bore it with a highspeed metal drill (get the electrics out first).

335C