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I finally tracked down the source of my engine vibration and starter grinding. The flexplate is warped and the ring gear is running about .050 out of round. The crankshaft and TC both run true.
I have read through lots of old threads on repeat flexplate failures and also read TSB 99-23-6. Apparently some of the spacers between the engine and transmission were not machined flat, which causes a TC preload and early failure.
Has anyone had repeat flexplate failures or seen these bad spacers in the field? If so, how far off parallel were they? Are there any aftermarket flexplates out there worth considering?
I don't know if my truck has had any prior failures or not, but I really only want to do this job once .