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Old 07-01-2010, 09:28 PM   #1
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Starter/flywheel Issue. grinding, Car will not start.

I also posted this here because i wanted the pros/Focus guru's to see this thread. And the car is turbo'd.
I just put a new built motor in. I also got a brand new CM stg 4 clutch kit (including flywheel). I went to start it for the first time today and there was nothing but grinding. I swaped starters and the same thing. i hit the key and it grinds. I have tested the solenoid and it pops out like it should. Then i removed the starter again and saw that there was some fresh metal on the out edge of the starter gear (not the teeth) and there is a burr on the flywheel from where the starter is hitting it.
It seems like the flywheel is a hair to big and the starter gear is hitting the side of the teeth and not the top and meshing.

What are the o/d of the zetec and svt flywheels. is it possible that CM put the wrong flywheel in the box and the SVT is a hair bigger??? or is it also possible that maybe when the tranny and motor was bolted together it is off by a C-Hair??? i need help my car has been down for 2 months....I just want to drive it..


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Old 07-02-2010, 05:35 PM   #2
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i have tinkered with it some more with no results. the starter gear is deffinitly hitting the side of the flywheel teeth. what could cause the flywheel/starter to be miss aligned? or is that even possible. I dont think it can be the wrong flywheel because everything bolted up perfectly with zero binding or clearance issues. is it a possibility that Clutch Masters put the wrong starter ring on the flywheel?
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Old 07-03-2010, 10:10 AM   #3
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Loosen both starter bolts just slightly and move the starter as far away from the flywheel as you can , holding it (pry with screwdriver) why some one tightens bolts and try that , if that does not work move it closer and tighten why holding , I have had to do this before also try rotating the starter to move away , hold and tighten , its a very close tolerance

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Old 07-05-2010, 03:51 PM   #4
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i ended up putting a washer in the top bolt and it worked. but i dont know if i should run it like that all the time or if i should find a solution
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