1980 Bronco was 302 with bad starter noise(like it is shimmed wrong if chevrolet) changed to a rebuilt starter same noise.
Swapped in 351W with new flex plate & starter same noise. Used bronco too hard broke transmisssion case replaced with a used & rebuilt trans (C6) and used plate between engine & trans. same noise. Shimmed starter with a motormite shim somewhat less noise but still the same. have tried AutoZone, NAPA, Wilson & used OEM ford starters to no avail. Starter still makes noise ane evenually ruins drive & nose cone on starter -- seems to crank slower than I think it should also. Any suggestions
Thanks

 

bpete

I can't say this is your problem, but it was mine.

When I rebuilt my 460 a while back, I replaced the original Ford flexplate with an aftermarket one because of some normal tooth wear. Afterward it sounded just like you mention. Like an old Chevy that needed the starter shimed.

Drove me nuts, it sounded like crap everytime you started it. I knew it did not sound like that with the OEM flexplate on it.

Long story short, had the engine back out to re-do some bad mistakes caused from a moron that claimed to be a machinist at a local NAPA store. I hunted down a OEM flexplate from Ford and installed it when re-installing the engine, sounds fine now.

I closley examined the teeth on the two, same amount of teeth, just the tooth pitch is closer together and tapered more on the outside (or top of the teeth) on the OEM flexplate, letting the starter drive engage them easier. It was banging itself into the teeth before on the aftermarket one. It already had some noticeable wear on the edge of the teeth where the drive was engaging. I replaced the starter again, because the teeth were already wearing on it too.

 

I have a 1980 F-150 Custom with a 302. Shortly after I bought it The starter was making a horrible grinding noise when I tried to crank it. After going through several starters and solenoids, I refocused my attention. I took the truck to a transmission shop. They said that it was the flywheel. They said it was cracked around the crankshaft (I don't know if that was the truth though). When I got it back, it cranked fine everytime. That is until I replaced the engine. After the install the starter went back to grinding everytime I tried to crank it. I was a little angry after spending over $2000 on the engine rebuild, and I couldn't even crank it. So I go out and buy a little Blazer for $1500 and started driving it. Shortly there after the dang starter just stopped making noise. This has been over a month now and it still starts and drives just fine. I'm sorry i don't have a real answer, these trucks are just a little moody. If you do find out what actually causes this problem let me know!

 

Mine never stopped making noise.

The engine was in for a little over a year. Sounded like crap everytime you hit the starter.

bpete

Did your noise just come about one day with the 302? Or had it always been that way?

 

When I bought the truck it didn't really sound right but it got worse after I bought it. The odd thing is, the guy I bought it from said he just spent $400 on a starter and flywheel, which of course was a lie. But anyway, try this:

Make sure you have a good battery( We all know how much power it takes to crank one of these bad boys), then check all of your battery cables. If any wire is exposed or if your clamps are corroded replace as needed. What happens is the starter doesn't get all of the power it needs to fully mesh with the flywheel if it is losing juice on the way there.

Just last night my truck did the grinding thing again. I got out and checked and sure enough my ground had wiggled loose. After tightening the clamp, it cranked right up.

this might not be your problem but it is worth a shot, definitely cheaper than messing with the flywheel or starter

 

get some one to help you and loosen the bolts on your starter, lay down and move the starter then have some one hit the switch (make sure the truck is out of gear) do this a few times and see if it works. I had the same kind of problem on an 88 302 with a manual transmissio. The flywheel had bad teeh so I replaced that and still noise. After some checking and messing found out that the starter just wasn't in the exact position.

 

that is the same thing my truck is doing. it also has a 302 and now it sounds like the starter gear isnt throwing out but it's just not hitting the flywheel. but if i turned the the engine a little by hand and hit the starter it statrs but it souonds horrible.

 

Might need a new flywheel or starter gear if it has kisked in but not started.