I had a recent problem with the starter on my '89 F250-460. When I went to start there was a rough shaking when the starter was engaged. I'm talking very rough, Richter Scale rough! And it didn't start. The entire engine shook. At first I thought the bendix wasn't engaging the flywheel due to low power, so I tried to jump it. Same thing. Not a voltage/current issue. As I was in a remote location and had a camper on it, towing wasn't an option so I just went for it. Eventually the engine turned over and I was able to get it home. I've started it a number of times since and the problem has not happened again.
I went to remove the starter today and found the top bolt-head was broken off. It is an old break too. I loosened the bottom one and tried to pull off the starter, but 16 years of corrosion hold the starter firmly in place. I retightened the bottom bolt and checked to see how tightly the starter is against the engine. It seems good.
Based on the fact that I've had this truck for 6 years and never had this problem before, I suspect there is a broken tooth on the flywheel not the bendix gear. That should give the very rough start as the starter turned the engine for 1 tooth then the engine came backwards against the bendix when the missing tooth came into play. Hence the "slap" as it tried to turn again.

So now for the big question. If I am correct in my analysis, will the missing tooth rest harmlessly in the bottom of the flywheel well, or can it interfere with other moving parts?

I'm hesitant to replace the starter as this one seems to be better than many of the rebuilt ones I've heard about.

Thanks for any help/opinions
Ingy

 

To answer your "big" question, if it is just teeth, they should lie there with no problem.
However, that is not the biggest question.
Your biggest problem is a combination of the starter AND the flywheel.
You need to fix that busted bolt first. If you don't, you run a real risk of cracking the bell housing or ruining the block plate. It is the old principle of action-reaction. The starter pries tremndous force against the bellhousing/block plate to provide the opposite torque necessary to turn the engine over against compression. If it isn't properly mounted, it will eventually waller out the block plate hole and probably crack the bellhousing.
As a matter of fact, misalignment of the starter MAY have been the problem you described. If it is "stuck" in there, it may be due to already having walked around in there, and is wedged in.
Secondly, if the flywheel is missing teeth - and it may not be - you can check it by pulling the starter, and checking the flywheel's condition through the hole. Turn the engine over from the front with a breaker bar/larger ratchet and socket.

I cannot emphasize enough how important it is run this issue down to ground. Next time it happens, and it will happen, you will probably not get out of it again so easily.

 

The starter problem has risen again, but a few more facts.

First, the bolt is NOT broken on the starter. I had figured that both bolts would come from the same side (starter side). Duh. The upper bolt comes from the opposite side of the bell housing. So it was the end of the bolt that I thought was the broken head. OK, so both bolts are fine.

Second, I don't think it's a tooth problem. It's not as rought as I originally thought.

Third, the starter is getting a chunk of current. Both battery cables are getting hot when I try to start it too much. The battery is fully charged and holding its charge.

Fourth, the solenoid only clicks once when the ingition is engaged and once when released. It does NOT click 1 time for each chatter of the starter.

Fifth, I believe I have the older style ('89) starter as the battery cable has to pass 'thru' the starter solenoid and there is just the one lead to the end of the starter.

So to review, when I try to start the engine, there is a rough chattering of the starter and you can even hear the clicking of a relay (not the one on the wheel well). Sometimes the engine will eventually start, other times it doesn't.

Wuts bust? Thanks

Cheers
Ingy

 

The busted bolt was good for a chuckle! I honestly had not thought about that and now I wonder how many of us have made that same assumption. You need a quality remanufactured stater. You can also buy a high torque starter for your truck off e-bay or JEGS. Most likley a quality reman will solve this issue for years.

 

Go for a high torque aftermarket starter. Smaller, lighter, stronger than a factory starter.