Starter grinding flywheel

Sounds like one of the following:
- clutch is completely worn.
- clutch fork mechanism is jammed or mis-adjusted and holding clutch away from flywheel
- shifting linkage is broken or out of alignment and is not really moving gears in the transmission into gear
If you didn't hear any bad sounds like banging or grinding, it's probably just a really burned out clutch. I'd also get a new pressure plate while your in there.

when replacing a starter motor, some have shims or spacers to make correct distance when installed. if these wre left out on instalation this will cause the problem. another problem can be incorrect number of teeth on starter motor which will cause grinding sound and prevent correct meshing of teeth on flywheel
it is also common to get a bad new starter
check solenoid

it sounds like it is either your clutch or the throw out bearing. either way you more than likely need to have to install a complete clutch kit (pressure plate, clutch disc, throw out bearing, and have your flywheel resurfaced.

2 possible things, 1. the contacts in the solinoid on the starter are bad, it would still test good but wouldnt have enouph power to engage the flywheel, replace starter, or 2. bad flywheel, teeth on flywheel are worn or broken, both require removal of starter, remove starter first inspect flywheel for damage, if none replace starter.

the syncro inside the trans is going bad. go to a trans shop or install a low mileage used trans. best of luck

the sound you hear is the starter grinding against broken teeth on the flywheel, for that to be repaired the flywheel on the vehicle will need to be replaced.

MIKESTA

Shims, are to space the starter drive gear away from the flywheel. The shim is inserted between the engine block, and the starter. The thicker the shim, the more the starter drive gear is further away from the flywheel.

Starter housings are machined from the factory, where they were made. No two housings come out the same, for the machined pad, where the starter bolts to the engine block.
The difference is minimal, granted, but thousandths of an inch count in this area.

It's generally a trial an error situation. This is why there are shim packs. Packs of shims with varying thicknesses.
Rule of Thumb, is generally that the starter drive gear, is 3/32nd's of an inch away from the flywheel.
If you hear a metallic grinding kind of sound, the starter is too close. A thicker shim is needed.

I suspect your problem is the starter drive itself. Definitely sounds like it from your description.
Granted, when bench testing the starter drive kicks out, but the roller clutch inside the Bendix drive is no good. (Starter drive)
Suggest you take the starter back, and get an exchange.

This rebuilt starter has a bad Bendix drive.

sounds like the flywheel may be cracked

You may need to install what they call shims in between the starter and the flywheel in order to align it correctly with the flywheel

the noise might be from a loose bendix on the starter,
the bendix is a little gear in fron of the starter see if there is any visual point to see it nad make sure it keeps away from the flywheel if not have the starter repalced, this bendix have a spring to keep it away from the flywheel also with a flash ligh try to see the closes you can to the center of flywheel sometimes they get crack where they atached to the engine,
and on the shifting might be a bad transmission or the shifter has to be inspected for your mechanic