Starter and flywheel gear inadequate mesh | Ford Explorer Forums - Serious Explorations

  • Register Today It's free!

Starter and flywheel gear inadequate mesh

jr7588

New Member
Joined
January 2, 2023
Messages
1
Reaction score
0
City, State
Fairbanks, ak
Year, Model & Trim Level
1994 Explorer 2D
4.0 sohc with the manual transmission

The truck has had a questionably done clutch replacement at some point.

The starter that was on it when I got it only engaged about 0.08" of the flats on the ring gear. I replaced it with the model Napa recommended when I discovered it was unreliable. This model had the same problem. I tried an auto zone model and same thing. All the starters still work and all the bendix gears slide a similar distance. Geometries regarding gear size, # of teeth, and depths from the mounting bosses seem the same. Is there more than one starter/flywheel combination for the 4.0 sohc manual? Is there an operable but incompatible flywheel that could be installed?

No crank endplay and the clutch works quite well.
 






If you have a 94, it has the 4.0 ohv, not sohc. The sohc is Gen2 and up.
There’s a difference between starters for auto trans and manual trans, maybe parts stores are giving you auto starters?
 






Back
Top