Starter issues - TC gear hits when rpm rise

[Demonic]

Good friend of mine just swapped a mid 70’s 440 into his original 400 equipped D100. Kept the same weighted converter. Flexplate was checked for bends and cracks. He’s had 2 mini starters and lastly a full size original starter on it. All three have issues with the gear catching as the rpm rises above idle speed. I’m thinking maybe a thrust bearing issue? He shimed one of the minis out with washers, no help there. Anyone run into this problem?

 

[Demonic]

No one?

 

[RemCharger]

Checking thrust play isn't a bad idea.

 

[Fran Blacker]

Does the move if you put it in gear? Thinking T converter not in front pump teeth.

 

[Geoff 2]

Could be the thrust brg [ #3 mains ] is worn. If it wears, it is usually the rear, such that the crank [ & the TC ] move forward & the ring gear hits the starter gear. Lever backwards & forwards on the crank & look for movement. Should be 0.002-007" from memory. For this to be a problem, you would probably need 0.030-0.040" of movement.
Other possibility. Flexed plate has flexed too much & now too close to starter.