94 Villager - Starter/Fly Wheel problem?

[DownloadThis]

About 2 months ago, I noticed that my villager became more difficult to start. As it became warmer out, cranking could last between 7 and 9 seconds regularly before the engine would start.

One day, I noticed the cranking was very slow and drawn out sounding (like it was dying). The van started fine and got me to work.

That afternoon, when I go to start my van, nothing happens.
I'm turning the ignition, but the starter does not even attempt to crank the engine. There is no sound.

I have PepBoys tow my car and take it in. (This is a nightmare in itself. I'm 40 miles from home, and they are refusing to fix my car despite what their 800# says. After some arguing, I'm able to get someone to fix the problem).

The problem (they say) is my starter. Basically, it's shot. So they put a new one in. Now, I have a new starter, but my car is making a bad noise everytime I start my car.

The cranking is very hard. The car starts pretty fast, but the starter does not stop when the engine starts. So everytime I start my car, I end up grinding the flywheel for at least 1 second. (I'm told that this is what's happening. The sound it makes is the same sound your car would make if you attempted to start it with the engine already running).

I'm at fault for not reporting this problem right then and there. I was stressed out and decided to ignore it and drive home. I thought that this "problem" was only temporary since the starter was new, and once broken in, would be fixed.

2 months later, and I'm still grinding my flywheel everytime I start the car. I finally decide to take it back to pepboys. I figure that the starter was installed wrong. The mechanics at PepBoys acknowledge my problem. The thing is, they replace the starter (still under warranty) and my car is STILL making this horrible noise. They tell me that my fly wheel is severely damaged and needs to be replaced.

I NEVER had this problem until they originally replaced my starter. The mechanic must have damaged something that day. Unfortunately, I have NO WAY to prove this according to them.

So now I'm stuck with a damaged fly wheel, which I believe is damaged by PepBoys.

What do you suggest I do?
Is replacing the fly wheel a major repair? How much would something like this cost me at a Meineke, or other transmission place?
I have no money to fix this. I'm forced to start my car everyday (resulting in more damage) until the flywheel is completely shot and the car will not start anymore. How much time do you think I have?


I know this is a bit wordy for my first thread here. I appreciate any help you can offer.

[aaamillertime]

To me it sounds like the starter bendix isn't releasing back into the housing after you let go of the key when the vehicle starts. I would ask them if they replaced your solenoid along with the new starter. A bad solenoid could be a possibility.
Also another thought would be. Sometimes vehicles have shims in between the starter and tranny to space it out evenly. Maybe they didn't replace shims and that could cause the bendix to bind up and not return to the starter housing immediatley.

Keep us posted. I'm very interested to know myself.

[IH8SPM]

There are no shims so the starter will always be straight. The starter teeth are made of a softer material than that of the flywheel. You may have another problem and Pep boys is not the best place to go. I would call the corp number and explain the situation but do not include the its my fault part. You told them of the problem and they said to drive off no your car is damaged and you need for work. You have tried in vain to get them to fix it and the refused all the way up to the manager so you had to call this in. Good luck and post info

[DownloadThis]

PepBoys made right.
I got in touch with corporate and the rep I spoke with was very helpful and kind. In the end, PepBoys had one of their transmission mechanics come to my local PepBoys to work on my car. It was a 2 day ordeal.
In the end, he replaced my Starter, FlyWheel, and Alternator.

The mechanic told me that the wrong type of starter was installed my car (which is why I began experiencing trouble immediately rather than over a period of time).

With the new starter and flywheel, my car starts perfectly and without that grinding.

Thanks for the replies. I believe that my being able to explain myself and problem more clearly helped speed along the process of having my car fixed. I knew more about the problem and was able to communicate better to PepBoys corporate.