We just replaced the old dual mass flywheel with the LuK kit. When I tried to start it, the starter engaged but didn't turn. Turns out, the solenoid wouldn't travel far enough to meet the contacts that send power to the starter motor. I put two pieces of 16 ga stainless between the starter and bellhousing, and the starter works most of the time. Occasionally, it takes several tries to get the starter to turn. Any ideas where the problem lies?? The starter gear and flywheel don't show any unusual wear.

Ed

 

which starter are you using delco or mitsu? both are interchangable but pay attention to the gear pitches. have you blued the teeth and checked for mesh?

 

It's a Delco, don't think it's a mesh issue as it only happens occasionally.

 

have you checked voltages at solenoid for drops

 

Voltage at solenoid looks good. I did have a weak battery this week and replaced both batteries last night.
Ed

 

just had a thougt did you have a problem prior to the swap if so have you taken the starter apart to check the wishbone lever that moves the bendix to see if is not bent or distorted or the bendix itself my need some attention like filing the edges but be careful not to mess the mesh too much

 

No problems prior to the swap. With usage, the problem is getting better, I think it's a clearance issue related to the bendix length of travel. Lately, it happens about once every 15 starts, down from once every 3 or 4. Think I'll wait and see......
Ed

 

keep an eye on ring gear have checked the bushing in the nose cone of the starter good luck