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Test D: Starter Noise Diagnosis

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NOTE: Inspect the flywheel ring gear for damage or unusual wear.
NOTE: Shim the starter if applicable.
NOTE: In order to add pinion to ring gear clearance a full size shim must be used. Do not shim only one starter mounting bolt. There are 3 shims available in different shapes for clearance. All are 0.039" (1 mm) thick.
  1. Did you preform the DIAGNOSTIC SYSTEM CHECK (ENGINE ELECTRICAL)? If yes, proceed to next step. If no, see DIAGNOSTIC SYSTEM CHECK (ENGINE ELECTRICAL)  .
  2. Start the engine. Does the starter operate normally? If yes, see INTERMITTENT OR POOR CONNECTIONS  . If no, proceed to next step.
  3. Start the engine while listening to the starter motor turn. Is there a loud "whoop" which may sound like a siren if the engine is revved while the starter is engaged after the engine starts, but while the starter is still held in the engaged position? If yes, go to step  6 . If no, proceed to next step.
  4. Do you hear a "rumble", a "growl", or, in some cases, a "knock" as the starter is coasting down to a stop after starting the engine? If yes, go to step  7 . If no, proceed to next step.
  5. This is often diagnosed as a starter drive gear hang-in or a weak solenoid. When the engine is cranked, do you hear a high-pitched whine after the engine cranks and starts normally? If yes, go to step  8 . If no, go to step  7 .
  6. Inspect the flywheel ring gear for chipped gear teeth, missing gear teeth or milled teeth. Is the flywheel bent, or does it have damaged teeth? If yes, go to step  9 . If no, go to step  10 .
  7. Remove the starter motor. See STARTER  . Inspect the starter motor bushings and clutch gear. Does the clutch gear have chipped or milled teeth or worn bushings? If yes, go to step  10 . If no, go to step  9 .
  8. Shim the starter motor away from the flywheel by adding shims between the starter motor and the engine block one at a time. Flywheel runout may make this noise appear to be intermittent. When complete, go to step  11 .
  9. Replace the flywheel. See ENGINE FLYWHEEL in ENGINE MECHANICAL. When complete, go to step  11 .
  10. Replace the starter motor. See STARTER  . When complete, proceed to next step.
  11. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If no, go to step  3 .
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