All Small Six My Car EATS starters!

[Rev.LowBuck]

I've posted starter woes a few months ago and now I'm back with more.

'63 Falcon with a '68 200, Large Log Head, Autolite 2100 on a VI adapter, Header, DSII distributor with GM HEI Ignition (because my DSII module puked), C4.
This car starts instantly every time I hit the key unless it's been sitting for a few days, then it starts almost instantly.
Runs like a champ, I drive it almost daily... but I've developed trust issues.

I went through 4 AutoZone starters over the course of 9 months or so. Some of them had fitment issues, wouldn't work right until I backed the bolts off a bit. I gave up on AutoZone and went to NAPA.

When I installed new NAPA starter I thought the issue was solved, everything was great, no troubles, no adjustments.
4 months later it's having trouble engaging the flex plate. Lots of awful grinding noise and will only catch briefly. Fortunately, the car starts well so it usually takes less than 2 revolutions to get it to fire but I'm reluctant to take the car anywhere for fear of having to walk home.

Battery cables, Solenoid and Power cable to starter are new. Voltage is good, Grounds are good. Transmission is properly mated to the block, Flexplate is properly mounted to the crank. The car does not run hot, spark plugs are evenly colored.

Could it be the #6 tube on the header be killing these starters? I think I've replaced one Ford starter in 30 years of owning 60's Fords. Now I'm doing it every few months. Before I installed the header I heated it and beat some clearance into it for the starter's sake. I used a relatively cheap and thin starter blanket (a nice thick one wouldn't clear) on the last AutoZone starter but did NOT install it on the now failing NAPA part. I know plenty of people are using headers but I'm not seeing complaints of failing starters any header discussions.

I'll hit up NAPA for a replacement. I'll use the blanket on the new one and maybe pipe wrap on #6 tube. The good news is that with all my experience I can change a starter on this thing in about 10 minutes without getting my hands dirty.

Anyone else dealt with this?
Any suggestions?

 

[Rev.LowBuck]

Just took the starter off to return to NAPA.
One of the ears was broken on the housing. I guess that explains it.
I was careful on the install to tighten the bolts gradually and evenly, working around the circle of bolts.
It did NOT break on install as everything was great until a week ago.

 

[DON]

Don’t know how this post got missed
It sounds like you are having a problem with the starter engaging, corrrct?
Remember it has to engage the teeth on the flywheel too, maybe your flywheel needs replacing . How old is the flywheel?
If this is the case, and you do get stuck away from home, pop the hood, rotate the engine with the fan, and that will usually get you home. But that is a bandaid not a fix

 

[drag-200stang]

Ford starters do not have a heat problem with headers, a least not on our sixes. I think that is bad starters or something else. The parts you get today are junk.

 

[Rev.LowBuck]

Thanks for the replies DON and Drag,
I assume the flex plate is original to the 1968 motor. I looked at the flex plate through the starter hole, didn't drop the inspection cover. It looks OK, some wear but nothing alarming.

I Installed another remanufactured NAPA starter this week. It works but it's noisy enough that I think there may be minor alignment issues.
I'll back the bolts out a little bit and see if it finds a happier place and retighten. I've not seen any procedures for aligning Ford starters, just bolt them in, evenly tightening around the circle. No shims or any of that other GM nonsense. Are there tricks I should know?

NOTE- I'm not cranking the starter bolts down super tight. I'd call it "pretty snug" with a 1/4 drive ratchet. Lock washers are used on each bolt.

 

[wme013]

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[DON]

I don’t think the torque on the mounting bolts is the issue. If the starter is engaging the flex plate and there is excessive noise, I would try putting washers (spacers) between the starter and the bellhousing. Starting with one on each bolt, then another if necessary. I had to do this ……back in the day…….on a stang with a 289. It quieted it down and never had a problem.
Maybe find a new starter, not rebuild. It might be possible that a bushing or something similar in the bendex is wore to the point that it is letting the gear travel too far out. You might be able to take the bendex off and put a washer or two ( after you find out if spacing it out helps) on the end of the starter shaft which would limit how far out the gear moves.
This is a different problem than the noise made by the starter not engaging the flywheel when cranking. Both make nerve grating noise!! Still not sure which one you are dealing with?

 

[bmbm40]

Thanks for the replies DON and Drag,
I assume the flex plate is original to the 1968 motor. I looked at the flex plate through the starter hole, didn't drop the inspection cover. It looks OK, some wear but nothing alarming.

I Installed another remanufactured NAPA starter this week. It works but it's noisy enough that I think there may be minor alignment issues.
I'll back the bolts out a little bit and see if it finds a happier place and retighten. I've not seen any procedures for aligning Ford starters, just bolt them in, evenly tightening around the circle. No shims or any of that other GM nonsense. Are there tricks I should know?

NOTE- I'm not cranking the starter bolts down super tight. I'd call it "pretty snug" with a 1/4 drive ratchet. Lock washers are used on each bolt.

So you have had several starters on it recently but only this last one is noisy which just adds to the mystery. I'm sure the original starter was used for core but if you had it maybe they can be rebuilt. And as stated new parts are usually crap. Hope you get it fixed.