Starter gear
 

Newer style, smaller starter. After the truck starts, it sounds like the flex plate taps something a couple of times. Then quiets down at idle. Revving does not change anything. When accelerating, it makes a similar sound, but less aggressive. It looks like the starter gear does not retract all the way into the starter housing. When I push on it, the gear goes back far enough so the leading edge is inside the nose come. When I release pressure, it drifts back out a bit. Shouldn't this stay inside the nose come?

Shiming it does not change anything. Right now,I have more than 1/8" between ring gear starter shaft. Probably too much.

Re: Starter gear
 

I had one break the fork that retracts the bendix. And it would bounce off the flex plate and make a horrible racket.
Died after a wiring order malfunction with some extended cranking.

Re: Starter gear
 

Flex plate bolt not tightened enough or has a washer under it.

Re: Starter gear
 

No washers. Possible one is loose.

Re: Starter gear
 

The stock ones have somewhat of a small or shallow/short profile. I believe they are a grade 8 with a fine thread. If they stick out too much they will tick or knock against other equipment like the starter and such.

I have seen it before, not tightened enough, or loosened up ticking on the starter.

Hope this helps! Flex Plate to Torque Converter Bolt to be specific.

Re: Starter gear
 

The unsupported nose Hitachi style starters come with a spacer ring that moves the drive gear further away from the flexplate.

Re: Starter gear
 

Found the video of what my starter did.

https://youtu.be/g-pkemjgaPs

Re: Starter gear
 

Interesting, it was just sliding back and forth. Mine does not do that.

Re: Starter gear
 

Yeah, still started a 454 fine. Just randomly bounced off the flex plate made an awful racket.

Re: Starter gear
 

While fixing a leak on the rear, I swapped back in the old flexplate. First thing I noticed was the ring gear was centered on the starter opening. The other was closer to the starter. I think the new flexplate had the ring welded on off center. Starter sounds much better.

Re: Starter gear
 

Good you found it. Chasing noises and vibrations is frustrating