Welcome to 2CarPros.
If it doesn't do it all the time, shimming won't help. Also, I have never seen shims on these vehicles. I will say that there were two different starters that were used. One was manufactured by Mitsubishi and the other Hitachi, so make sure the replacement is the same design. Since it makes the same noise with both starters, I question if the flywheel itself is damaged. The flywheel is the component the starter engages with to turn the engine. It has teeth on it and they can break, the flywheel can crack, or it can even become loose.
What I suggest is to remove the new starter and check the gear itself to see if there is any evidence of damage to it. Next, while the starter is out, slowly turn the engine from the crankshaft pulley and watch the flywheel for damage to the teeth as well as check to make sure it is tight.
If it is cracked, it may be hard to see. However, do your best to check.
Let me know what you find.
Joe
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Wednesday, March 27th, 2019 AT 7:09 PM