Starter Problem
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Mountain Pass
Joined: Oct 2005
Posts: 191
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From: NH
Starter Problem
This past summer the starter in my e99 would spin.....but not fully engage the flexplate. Starter was only 2 years old. So replaced the solenoid on it. Still occasionally did not fully engage. Tried a new starter. Same thing. New fender mount solenoid. No dice. Pulled the access cover on the bottom of the transmission. Flexplate teeth were chewed. Put a new flexplate in two days ago. Ahhhhgg. It did it again today. Starter turns over energetically. Both good quality batteries and have never needed jumping. Any ideas? Thanks
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Mountain Pass
Joined: Oct 2005
Posts: 191
Likes: 0
From: NH
Went to start it his afternoon and the starter spun.....but didn't fully engage the flex plate. 2nd try and all evening.... No problem. It will wear the teeth on the new flex plate if it keeps doing that.
Post Fiend
Joined: Mar 2007
Posts: 26,966
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From: Texas
You sure you have the right starter? I'd pull the starter and watch it engage to make sure the gear is getting kicked out all the way. Also make sure the teeth match the flywheel teeth.
How was it wearing the teeth on the flexplate? Just the forward half of the teeth or something different?
How was it wearing the teeth on the flexplate? Just the forward half of the teeth or something different?
Senior User
Joined: Mar 2012
Posts: 492
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From: Jenkintown, PA
Whose starter are you using? I went through 3 NAPA "lifetime warranty" starters that did the exact same thing. Replaced two flex plates and three starters before switching to a Nippon Denso. Expensive, but worth every penny IMO.
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Mountain Pass
Joined: Oct 2005
Posts: 191
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From: NH
Yes. Just the contacting edge of the flywheel is worn across a handful of teeth. But in a spot that the engine likes to stop at. Pinion gear on starters all perfect. Its the longer starter they put on the older trucks. Not the offset motor design.
Lead Driver
Joined: Jun 2004
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From: Amarillo, TEXAS!
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Mountain Pass
Joined: Oct 2005
Posts: 191
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From: NH
Longer planetary gear reduction. Has cranked fine until last spring. Oh.... And the Napa starters I have used were also junk. Contacts in the end cap vibrated loose in just one month. But those Napa starters never chewed the flywheel. ....they never even clicked. Just dead until I tightened the small screws on the cap.
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Senior User
Joined: Jan 2012
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From: Somewhere in Virginia
Looks nice and beefy
Senior User
Joined: Mar 2012
Posts: 492
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From: Jenkintown, PA
I bought mine brand new from:
Larryb - Ford fuel pump | Ford fuel hose - Foster Truck
It was $495.
Yes, I know that's about triple what the typical rebuilt starter costs, but I haven't heard that horrible grinding of bendix and ring gear teeth in over a year and a half. Plus, the engine spins up super fast.
Larryb - Ford fuel pump | Ford fuel hose - Foster Truck
It was $495.
Yes, I know that's about triple what the typical rebuilt starter costs, but I haven't heard that horrible grinding of bendix and ring gear teeth in over a year and a half. Plus, the engine spins up super fast.
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Mountain Pass
Joined: Oct 2005
Posts: 191
Likes: 0
From: NH
I'm going to look into a new quality starter. But it still bugs me that I can't figure out the root cause. I don't want to be stuck somewhere with a bad flexplate. I carry a spare starter. Maybe I should stock a flexplate too 
Senior User
Joined: Mar 2012
Posts: 492
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From: Jenkintown, PA
Trouble is, spare starters can be swapped out in a few minutes. Flex plates are a bit more difficult, especially in the field