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Starter engagement issues.


Terry

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I searched around here and came up with some posts with some of the same issues I am having. I have a 87 2.9 4 x 4 manual trans ranger. I bought this truck and used my 2 x 4 auto trans truck to combine them into a drive able truck. One of the issues was the motor had not been treated well and had a blown head gasket. Well, long story short I put my cleaned up parts from my old truck on the 4 x 4 and the starter was one of them. It lasted about 2 years then started making grinding noise. Last week it finished killing itself. The starter still cranked and the bendix spring was still working but it stopped engaging the flywheel. I pulled the starter dreading that I was going to see the teeth on the flywheel and starter wasted. The flywheel has some of the edge ground off of as well as the starter. I put in another starter I had laying around. The replacement starter lasted about a week and no longer engages with the ring gear as well. I don't know it the rangers have the same issue the the full size trucks have in that the position of the ring gears are not in the same place between the auto and manual trans trucks. The engagement area between the ring gear and the starter seem to be small and not engage the full width of the gears. I am thinking about putting in a new drive gear in my starter. A rebuilt starter is over 50 dollars and the drive gear is 10 dollars. I am trying to get thru the winter before I replace the flywheel, clutch, slave cylinder and reseal all the leaks on the transmission and transfer case. I'm not as young as I used to be and working in 25 degree temps on the driveway kick me in my ass.
 


enjr44

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I have never had a 2.9. However, I have heard there are at least 2 different sized flywheels used on it. Like you said.
 

adsm08

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Uh, no there weren't.

The 2.9 was the same size ring gear auto or manual. The 4.0 had a larger flyhweel for the manual.

You probably have a damaged spot on the ring gear that gets no engagement.
 

Terry

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Uh, no there weren't.

The 2.9 was the same size ring gear auto or manual. The 4.0 had a larger flyhweel for the manual.

You probably have a damaged spot on the ring gear that gets no engagement.
Is the spacing from the ring gear to the crankshaft the same distance?
 

Terry

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I ordered the new drive gear for my starter. Not sure it will help. I looked at the starter gear last night and the teeth are damaged on the top of the tooth. I will Mike the diameter of the new one verses the old one and see what I get. May start the tear down Saturday.

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The spacing should be the same. There is only one starter for the 2.9.
 

jeremysdad

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You probably have a damaged spot on the ring gear that gets no engagement.
This. You can keep throwing band-aids at it, but eventually, you'll get to where my Pinto was...had to rotate it a 1/4 turn to get it to start, initially...then the ring gear teeth ground down to where the starter wouldn't turn it a full revolution...

Trans removal and a new flexplate/flywheel. And a 20th new starter. lol
 

Terry

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This. You can keep throwing band-aids at it, but eventually, you'll get to where my Pinto was...had to rotate it a 1/4 turn to get it to start, initially...then the ring gear teeth ground down to where the starter wouldn't turn it a full revolution...

Trans removal and a new flexplate/flywheel. And a 20th new starter. lol
I am already planning on doing a full clutch job. I just sucks that issues always pop up in winter. I can get starter drive gears for 15 dollars. I will measure the outside diameter of the current starter gear an the new drive gear. If they are close to the same I will start the clutch job Saturday.
 

Terry

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Well I have removed the transfer case, transmission and the flywheel. The ring gear teeth are hosed. I ordered a new one as well as a clutch set. I am not sure that I should use the existing starter gear with the new flywheel.
 

Terry

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Well its been a while on this post. I pulled the motor, trans, transfer case. Almost everything except the axles and suspension have been re-sealed and or replaced. I have a new starter, flywheel and clutch. I went to start it and it is grinding. From what I have seen, the starter gear and flywheel ring gear should be the same for automatic as well as stick. I think tomorrow if it does not snow, I will loosen the bolts and make sure the starter is pushed as far to the flywheel as possible. It that does not fix it, I will have to get out my dykem and check the mesh between the gears.
 

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Very common apparently...and not just with the 2.9L v6 either. My 84 2.8L v6 Bronco 2 had the same damn starter issues, except with mine the starter would creep out of position slightly and then it would start grinding, then a free spinning starter not engaging the flywheel at all...flywheel was not damaged, don't know why but once you replace the starter they seem to have this issue. I even went so far as to drill the holes for the starter all the way through and put bolts with lock washers & lock nuts on them...starter would still slip out of position after a few starts. Never figured out the problem but there is only 1 starter option on them so its not a manual versus automatic issue...at least there's no way to know because you are only offered 1 starter no matter which transmission you have LOL.
 

Terry

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If its not snowing tomorrow afternoon, I will get under the truck and see what I can do.

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