I have a 1996 Chevy Tahoe 4WD, 4 Door, Auto, 5.7L Engine. I have replaced the starter 6 times in less than a year. Each time I replace the starter, it works for about two weeks and then it has an extremely loud grinding noise. On two occasions the nose cones of the starters have broken off and I had to retrieve them from inside the bell housing. I checked the fly wheel and there are no damaged or missing teeth. I just replaced the Crank Position Sensor and that did not correct the problem. I am now at a complete loss as to what to do next.

I have a 1996 Chevy Tahoe 4WD, 4 Door, Auto, 5.7L Engine. I have replaced the starter 6 times in less than a year. Each time I replace the starter, it works for about two weeks and then it has an extremely loud grinding noise. On two occasions the nose cones of the starters have broken off and I had to retrieve them from inside the bell housing. I checked the fly wheel and there are no damaged or missing teeth. I just replaced the Crank Position Sensor and that did not correct the problem. I am now at a complete loss as to what to do next.


I have found many starters supplied are crap///like autozone ...
I have used many times USA INDUSTRIES as my choice of replacement...reasonable cost and so far no shimming required...

the starter drive teeth when the solenoid is engaged must have 1/8 in clearance to the flywheel teeth.. use 12volts to the solenoid terminals to make this check no wire to the starter motor armature [big wire] the flywheel must be inspected fully [rotate] to be sure no teeth are in need of filing..

the connections [all] must be secure...even the one that has no wire going to it...

even the pros F this up,,,you can do it..

i just went through this exact thing with my tahoe. the doctor that sold it to me had reciepts for 4 starters that have been installed in last 2 years, all by dealerships. Recheck your flywheel. i thought mine was fine till i made another inspection . i found several worn teath. appearantly the starter stops in or around the same place. I replaced the flywheel friday , and the starter sounds much better. btw it is possible to change the flywheel without removing the tranny. we unbolted it and shifted it back about 2 inches. goodluck