For 1990-2009 cars

### Diagnostic Aids

• | Inspect the flywheel ring gear for damage or unusual wear.

• | Shim the starter as required.

• | 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 three shims available in different shapes, for clearance, all are 1 mm (0.039 in) thick.

Step | Action | Yes | No
--- | --- | --- | ---
1 | Did you perform the Diagnostic System Check - Vehicle? | Go to Step 2 | Go to Diagnostic System Check - Vehicle
2 | Start the engine. Does the starter operate normally? | Go to Testing for Intermittent Conditions and Poor Connections | Go to Step 3
3 | Start the engine while listening to the starter motor turn. Is there a loud "whoop" it 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? | Go to Step 6 | Go to Step 4
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? | Go to Step 7 | Go to Step 5
5 | Important: 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? | Go to Step 8 | Go to Step 7
6 | Inspect the flywheel ring gear for the following:

• | Chipped gear teeth

• | Missing gear teeth

• | Milled teeth

Is the flywheel bent, or does it have damaged teeth?

Go to Step 9

Go to Step 10

7 |

1. Remove the starter motor. Refer to Starter Motor Replacement .
2. Inspect the starter motor bushings and clutch gear.

Does the clutch gear have chipped or milled teeth or worn bushings?

Go to Step 10

Go to Step 9

8 | Important: Flywheel runout may make this noise appear to be intermittent. Shim the starter motor away from the flywheel by adding shims between the starter motor and the engine block one at a time. Did you complete the repair? | Go to Step 11 | --
9 | Replace the flywheel. Refer to Engine Flywheel Replacement. Did you complete the replacement? | Go to Step 11 | --
10 | Replace the starter motor. Refer to Starter Motor Replacement . Did you complete the replacement? | Go to Step 11 | --
11 | Operate the system in order to verify the repair. Did you correct the condition? | System OK | Go to Step 3