Someone help! I have a 83 Bronco, 300/6cyl, AOD. It keeps breaking the mounting ears on the starters. Here is what Ive done so far.

Put a long block in 3 years ago. Flexplate was worn but it was only vehicle and it was late on sat night so we left old flexplate on it. Would put a new starter on it every winter because at -30 it would grind in the mornings. I assumed the starter teeth were just wearing down.

3 weeks ago I decided it was time because I had a starter break at the mounting holes. Replaced flexplate. The tin plate between bellhousing and motor was bent a little. Sledge hammered it back into shape. Put it all back together. 3 Days later mounting ear on starter broke again. Got pissed off and cut the tin plate (mabey it was still bent i thought). I have tried no shims (starter bolted directly to bellhousing), using one starter shim (made specifically for starters), and then tried 2 shims at once. Each time I have had the starter break at the mounting ears.

I have looked for cracks in bellhousing, the flexplate isnt hanging up or anything wierd when I turn it with screwdriver/socket. Was hoping mabey I got wrong flexplate but I counted teeth and there are 164 of em on the flexplate which I assume is correct.

When I turn it over with key the starter engages, it turns for split second and it sounds like it hesitates, then either it will turn over and start, or the starter breaks.

In the past month I have bought enough starters to have put a nice down payment on a new truck Anyone have any Ideas?

 

I would check the teeth on the flywheel or see if its warped in any way. Something has it in a bind.

 

I gave up and took it in to shop. They cant find anything wrong. They think mabey timing is off and it is causing flexplate to kickback and break starter. The also say #3 cylinder has issues. When they did compression test sometimes it would have pressure and sometimes it didnt. Mabey worn valve springs...