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You may need to add shims to increase pinion gear to ring gear clearance !
Inspect the flywheel ring gear for damage or unusual wear.
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Shim the starter if applicable.
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In order to add pinion to ring gear clearance a full size shim must be used. Do not shim only 1 starter mounting bolt. There are 3 shims available in different shapes (for clearance). All are 1 mm (0.039 in) thick.
When you took off the old starter did you see any thin strips of metal ?
When you replaced starter did you notice the condition of the
flywheel ring gear? My guess is the ring gear is very badly worn or somehow the positioning of the starter is such that it is off enough
that it runs into the ring inside the gear. Did you hit something in the road before this symptom started? Any chance someone tried to jack up the car and used the starter as a lifting point?
Accident? Are you sure it's your original engine? Ie they used to be very easy to change. Any other thing that would bend the mounting point on the engine? If manual transmission, try to move the engine a little by moving the car with clutch engaged.
If Automatic try to move ring gear with a tool if you can get to it.
If this action is sufficient to move the ring gear into a "good" spot
and the Starter will engage, you now know you have a few bad spots.
the ring gear on the fly wheel may have damaged teeth or not have the right gear teeth count to be compatible . Pinion teeth have to match the ring gear teeth or they have trouble meshing and that makes it hard to turn over. If the ring gear teeth have been damaged then the gear box will have to come out to get the fly wheel / flex plate off. If it is auto then it is a simple matter of replacing the flex plate . But if manual the ring gear is removed from the flywheel and a new one fitted. Most accredited service shops can do this operation. count the number of teeth on the ring gear and the number on the starter pinion and take the figures to an auto electrician and he will know it they are right.
If your testing indicates that the starter must be removed, the first step is to disconnect the negative cable at the battery.
It may be necessary to place the vehicle on a lift to gain access to the starter. Before lifting the vehicle, disconnect all wires, fasteners, and so on that can be reached from under the hood.
Disconnect the wires leading to the solenoid terminals.
To avoid confusion when reinstalling the starter, it is wise to mark the wires so they can be reinstalled on their correct terminals.
On some vehicles you may need to disconnect the exhaust system to be able to remove the starter.
Loosen the starter mounting bolts and remove all but one.
Support the starter while removing the remaining bolt.
Then pull the starter out and away from the flywheel.
Once the starter is free, remove the last bolt and the starter.
Once the starter is out, inspect the starter drive pinion gear and the flywheel ring gear.
Starter drive and flywheel ring gear wear patterns. Courtesy of Ford Motor Company.
When the teeth of the starter drive are abnormally worn, make sure you inspect the entire circumference of the flywheel.
If the starter drive or the flywheel ring gear show signs of wear or damage, they must be replaced.
Reverse the procedure to install the starter.
Make sure all electrical connections are tight.
If you are installing a new or remanufactured starter, sand away the paint at the mounting point before installing it. Also, make sure you have a good hold on the starter while installing it.
Many General Motors' starters use shims between the starter and the mounting pad.
Shimming the starter to obtain proper pinion-to-ring gear clearance. Courtesy of General Motors Corporation - Service Operation.
To check this clearance, install the starter and insert a flat blade screwdriver into the access slot on the side of the drive housing. Pry the drive pinion gear into the engaged position.
Use a wire feeler gauge or a piece of 0.020-inch (0.5080-mm) diameter wire to check the clearance between the gears.
Checking the clearance between the pinion gear and the ring gear.
If the clearance between the two gears is incorrect, shims will need to be added or subtracted to bring the clearance within specs.
If the clearance is excessive, the starter will produce a high-pitched whine while it is cranking the engine.
If the clearance is too small, the starter will make a high-pitched whine after the engine starts and the ignition switch is returned to the RUN position.
Every starter should be bench tested after it is removed and before it is installed. to conduct a free speed or load test on a starter, see the free speed test.
If your testing indicates that the starter must be removed, the first step is to disconnect the negative cable at the battery.
It may be necessary to place the vehicle on a lift to gain access to the starter. Before lifting the vehicle, disconnect all wires, fasteners, and so on that can be reached from under the hood.
Disconnect the wires leading to the solenoid terminals.
To avoid confusion when reinstalling the starter, it is wise to mark the wires so they can be reinstalled on their correct terminals.
On some vehicles you may need to disconnect the exhaust system to be able to remove the starter.
Loosen the starter mounting bolts and remove all but one.
Support the starter while removing the remaining bolt.
Then pull the starter out and away from the flywheel.
Once the starter is free, remove the last bolt and the starter.
Once the starter is out, inspect the starter drive pinion gear and the flywheel ring gear.
Starter drive and flywheel ring gear wear patterns. Courtesy of Ford Motor Company.
When the teeth of the starter drive are abnormally worn, make sure you inspect the entire circumference of the flywheel.
If the starter drive or the flywheel ring gear show signs of wear or damage, they must be replaced.
Reverse the procedure to install the starter.
Make sure all electrical connections are tight.
If you are installing a new or remanufactured starter, sand away the paint at the mounting point before installing it. Also, make sure you have a good hold on the starter while installing it.
Many General Motors' starters use shims between the starter and the mounting pad.
Shimming the starter to obtain proper pinion-to-ring gear clearance. Courtesy of General Motors Corporation - Service Operation.
To check this clearance, install the starter and insert a flat blade screwdriver into the access slot on the side of the drive housing. Pry the drive pinion gear into the engaged position.
Use a wire feeler gauge or a piece of 0.020-inch (0.5080-mm) diameter wire to check the clearance between the gears.
Checking the clearance between the pinion gear and the ring gear.
If the clearance between the two gears is incorrect, shims will need to be added or subtracted to bring the clearance within specs.
If the clearance is excessive, the starter will produce a high-pitched whine while it is cranking the engine.
If the clearance is too small, the starter will make a high-pitched whine after the engine starts and the ignition switch is returned to the RUN position.
Every starter should be bench tested after it is removed and before it is installed. to conduct a free speed or load test on a starter, see the free speed test
You need a flex plate, ring gear or some call it a flywheel. Just make sure you ask any auto parts store or dealer & explain that it is for a 5 speed manual transmission. Dodge also called their version of this truck a D50.
The ring gear is mounted to the flywheel for your starter teeth to engage and turn the engine. Most all cars have this ring gear. If you are having problems starting it may be worn teeth at one point. Auto trans and manual trans will have a ring gear for the starter.
A lot of work !!!
The engine or gearbox will removing.
You will need to find a pre-engaged starter ring (not sure that one was produced)
Take off flywheel and change over ring gears.. then reassemble.
Why do you want to change it ?
Starter drive and flywheel ring gear wear patterns. Courtesy of Ford Motor Company.
Shimming the starter to obtain proper pinion-to-ring gear clearance. Courtesy of General Motors Corporation - Service Operation.
Checking the clearance between the pinion gear and the ring gear.
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