I am at my wits end with this.. It has a flexplate/flywheel issue... its a 4.0 automatic and have replaced it now twice... teeth keep getting broken off... have bought aftermarket and one from Ford Dealer and both have same issue... we shimmed the started on one and not on other and again teeth broke off... Does anyone have any suggestions or where I can maybe find an answer... thank you

 

What does the teeth of the bendix look like?

From the sounds of it, the Starter is chewing up the flywheel.

 

On the first one that was changed there was no damage at all to the bendix but we replaced the flexplate and starter and it did ok the first few starts then started grinding again.. and now it will not start at all just grinds. will take this starter out an look but the first one had no damage just the teeth broken off flexplate

 

This will be the 3rd time to replace this and so trying to figure it out before if maybe I've missed something ...

 

Just out of curiosity, did you change out the starter relay?

 

yes that part was changed on the last time around, flexplate, starter and relay ...

 

So what happened to cause you to replace these items?

 

I bought the van for 500. knew it had to have the flexplate changed so replaced it along with a new starter.. that was with the aftermarket flexplate.. lasted for about 3 months then started grinding again and got to where wouldn't start.. So went to Ford dealer bought the dealer flexplate again with another Starter and this time did the relay... and still the same issue and not its where it won't start just grinds.. appreciate any help , ideas

 

did this start with oem factory starter and flex plate with no prior major engine damage/repairs?

if not then:
bet there is a wire shorted out that is powering the starter up while rig is running down the road.

 

I agree, it sounds to me like the starter is engaging when it shouldn't be. I don't think your flexplate is the problem. The problem I think is either the starter, or an electrical issue.

 

The engine runs strong, no issues... if it were engaging while driving wouldn't there be some kind of noise? electrical? where do I start with that?

 

Ok while driving the vehicle the starter is not engaging... runs excellent when it runs... no other issues... i'm lost...

 

Can I ask is there something that may cause the starter bendix not to engage all the way into the teeth on the flexplate?

 

Usually the bendix is pushed out by the large solenoid on the side of the starter. It can stick when they get old and their lubricants harden due to dis-use. That's not likely with your new starter. The solenoid has a separate smaller wire that powers it when the key is turned to the crank position. If that wire is not de-energizing, it will push the starter gear out. But if that gear is always engaged to the flywheel, the starter will make screeching or howling noises when the engine speed gets beyond idle.

I'm wondering if the starter mount or bell housing has sustained damage that's causing mis-alignment of the starter?

 

starter out of align with flexplate
starter bendix not extending completely
bendix teeth damaged.
starter shaft bent
flexplate teeth damaged.

starter bendix shaft not the correct spec'd length, not the correct starter