Grinding of starter Pinion Gear

Tiny
SIERRA VAPE
  • MEMBER
  • 2011 FORD F-150
  • 3.5L
  • 6 CYL
  • TURBO
  • 4WD
  • AUTOMATIC
  • 182,000 MILES
When I attempt to start my truck listed above Platinum Edition, I hear a grinding noise. I purchased a new starter from my local Napa Auto Parts and had the starter replaced by a local shop and the grinding was lessened, but still persisted intermittently. I still used the truck as I could just turn the key off and back on a few times and one of those times it would start. Then a day or so ago I could no longer get the starter to not grind and start the truck. I then replaced the battery with a Gold Duralast 5-year battery and cleaned all the associated contacts to make sure they were sulfite free. It needed replacement anyway as I had it tested and was informed that the Cold Cranking Amps had diminished. I then removed the starter and took it back to the Napa Autoparts where it was purchased. They exchanged it with a new starter of the same type that I installed. I took a picture of the teeth on the flex plate ring gear before I installed the new starter. The same issue is exhibited with grinding on all start attempts. I am beginning to suspect that the teeth on the flex plate ring gear are worn and that requires replacement. I have attached a photo of the teeth and was wondering if this is the proper diagnosis? The teeth don't look too bad to my "untrained" eye.
Friday, May 27th, 2022 AT 4:52 PM

4 Replies

Tiny
SIERRA VAPE
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Picture.
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Friday, May 27th, 2022 AT 4:55 PM
Tiny
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Hello,

Did you inspect the starter that you returned to Napa for any damaged teeth?
From what you are explaining it sounds like the issue is worn teeth.
It's hard to tell from the picture, but keep in mind that you can only see a small part of the flywheel, so the rest could be in worse shape.
The only way to know for sure would be to turn the crankshaft manually and inspect the flywheel.
In order to replace the flywheel, the transmission needs to be removed.

https://www.2carpros.com/articles/how-flexplates-work

I have attached diagrams below for your reference.

Let me know of any questions.
Thank you.
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Friday, May 27th, 2022 AT 7:55 PM
Tiny
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The starter gear did not have any excessively worn teeth as it was fairly new. Installed on 2 -22-2022. Lots of 2's I know. There was just minimal scraping on the leading edge that would be pushed forward towards the flex plate. I was hoping that it was just an intermittent Bendix that was not consistently deploying the starter gear forwards to engage the flex plate (less cost associated with starter replacement). Truck has 182,000 approximately and would imagine the "life expectancy" of the flex plate is under that number of miles and starting processes. Are worn teeth on the flex plate just something that one should naturally expect? Does a starter that fails to deploy and is failing cause worn teeth on the flywheel ring gear? I was always under the assumption that the metal used to produce the flywheel ring gear was of a greater hardness and the starter gear was more of a sacrificial nature.
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Saturday, May 28th, 2022 AT 10:00 AM
Tiny
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It is possible to have a faulty starter, which is not engaging properly or all the way. Which will cause it to either free spin or grind.
It is not abnormal to have broken/worn teeth on the flywheel. Overtime with all those starts can ware and damage the flywheel.

Did you say you tried two new starters with the same issue?
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Saturday, May 28th, 2022 AT 7:35 PM

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