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Old 03-31-2009   #1 (permalink)
greg_true is offline Rookie

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Default 1984 2.3L starter motor not engaging flywheel

Having no luck trying to search this forum's threads for my problem so I will start with this and hope for a little help.
My Mustang is 1984 with a 2.3L engine, 1bbl (single barrel carburetor) 4-speed manual transmission. I am getting a feeling that it may not be original engine from factory.
I bought this car becuase I was in a pinch for cheap transportation. It started cranking really rough with the loudest cranking (starter motor noise) I ever heard. Two weeks later the starter would not engage to crank the engine - ziiiing-ziiiing! Pulled the starter to find the bendix gear badly chewed-up and the shaft it rides on was real loose becasue the end of it where a bushing could be was gone or none existent. Seller said the starter was new. Confirmed this was so by its looks and parts store said it was under warranty when look-up on their 'puter. Flywheel damage was not too bad. I filed off burrs on some teeth. But on the flywheel where the engine likes to quit about 6 teeth have a little bit of wear on the surface where the bendix gear engages.
The battery, starter relay, Positive cable battery-to-relay, cable from relay to starter, and Negative battery cable were all replaced just before I purchased car. Looks like somebody tried their best. I put the battery on a charger over night.
Next starter works good for about 2 weeks. At first it did not make loud noises - it cranked engine in normal manner and typical sounds. Then progressed to the point where it wouldn't engage flywheel. Pulling it showed less bendix gear damage than previous one and shaft end still very loose but again not so bad as previous.
Next starter cranked and started the engine once and then it refused to engage the flywheel - ziiing-ziiing! Pulled it and really no damage to gear or end of shaft. Next starter refused to engage at all. Previous owner unavailable for help.
Got a feeling this may not be the correct starter for this engine. At parts store I keep telling them its a 1984 Ford Mustang 4 cylinder. So weird that when I look at these starters with guys at the store and no two (current broken one and new off the shelf) ever look exactly alike at the nose-end. The starter I am given is an ULTIMA (ULT) - Remanufactured Starter Item #: 03-0385M.
I guess the help I need is how to identify what engine this is so I am sure I am getting the right starter. Any help is apperciated .
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Old 04-04-2009   #2 (permalink)
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Please help.
I work for minimum wage at Kmart part-time.
I cannot afford to donate right now.
Thank you for your kindness and I might someday return the favor.
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Old 04-04-2009   #3 (permalink)
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You need to replace the flywheel. There's a thread with this same problem from just a month or so ago.

You can put all the starters in there you want, but that bad spot on the flywheel is going to keep winning the battle.

Remanufactured starters are just that. They're built from bins of parts collected from core returns that for the most part are the same, but may have production differences depending on actual year of manufacture for the particular part. They don't exactly hire electrical engineers to rebuild these things either so a wrong part could have slipped by or even a wrong starter come from a correctly marked core box. It's hit or miss, and tends to be more hit than miss though.
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Old 04-11-2009   #4 (permalink)
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Thank you b_chandler for replying!
My next-door neighbor said same about the flywheel. Since my post I got some help from the local Ford Parts Dept. JW said to try a Motorcraft brand before giving up. He gave me some part numbers and I will go back to parts store and try to exchange for it.
When I get the right starter I post back here.
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Old 04-11-2009   #5 (permalink)
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Just make sure you change the flywheel before you ruin another starter. No sense in throwing good money after bad.
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Old 06-29-2009   #6 (permalink)
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i had the same problem if you go to a auto zone if you have one around where you live and buy a starter with a life time warranty they will replace it everytime.... although it will pass the test even if it is bad just tell them that the test just sees if it is popping out but there is no load to actually see if it is bad or good thats what i had to do and i argued with them for about half an hour before they switched it out
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