why would this keep happening?

[cta2885]

1991 Cavalier 2.2l 221k miles

The plunger on my starter keeps breaking. Which is making the bendix keep bouncing and grinding against my flywheel. Over the weekend i went and had my flywheel checked to make sure it wasnt that. but there isnt anyone that can give me a straight forward answer. The next starter i put on will be the 4th in less than 4 months. Please any suggestions will help

[cta2885]

ive heard many different things. Wiring? Flywheel warped? Heat? Shiming? im seriously because of this! SOMEONE PLEASE HELP!

[wrightz28]

How did the 'first' starter go out, same way, or this problem started occuring after that replacement?

[cta2885]

same exact way. i had my flywheel checked and its all correct

[wrightz28]

Manual or auto trans?

[cta2885]

auto

[wrightz28]

When you replace the starters, are you reusing the same solenoid on each one?

[cta2885]

no, its a whole new starter unit in one!

[wrightz28]

Well darn, there went that idea.

If the problem started (no pun) out of the blue requiring the original replacment, it can't be a shimming issue. No repairs were done recently prior to this problem?

Something must have moved out of proper alignment. Either the crankshaft or the converter in put shaft. A real far fetch all though not impossible, a loose bellhousing.

[cta2885]

Yeah thats why i cant figure out why. I was told i could have a cracked flywheel, but i also thought that if i had a cracked flywheel i would know for sure with the noise it would make. OR i have a backfire when i start my car. But when i start it, there is no backfire. So im totally lost?

[Blue Bowtie]

If the trans is a 1254C/3T40, and the TC thrust/pump bushing is worn enough after that kind of mileage, the converter could be pushing forward and taking the flexplate with it, reducing the required range of starter pinion throwout. That main drive chain setup doesn't really do much to hold the converter in place.

The next time you have the starter out, try to GENTLY push or pry the flexplate and TC back to the pump hub shoulder. If it moves back significantly (more than a few thousandths) you may have found the problem.

[cta2885]

ok so i put in the new starter, and did check for any movement with the pry and pull. there was no movement at all. No the starter says no shim, but could a no shim be my issue with the length of the bendix coming out and going to far?

[wrightz28]

Okay, yes, but reverting back to a question already covered: what caused the initial replacement of the starter, to wich you replied, this issue

[cta2885]

The solenoid just died. I mean i figured i would just replace the full starter rather than the solenoid. i did nothing different from taking it out to putting the new one in!

[wrightz28]

Okay, so this problem has now started as a result, right??? Then the issue is that it is not shimmed properly. Which is why I stated when you replied that this is the issue for the starter being replaced in the first place, I elminated shimming.