starter motor problems

please help fellow Windstar owners. I installed a new (rebuilt) starter and the engine starts but the starter motor makes a very ugly sound. I took the starter out and looked at it. The teeth have little dings in them. Is it due to gears not lining up. Is there a secret to line the starter gears up with the gears already in the motor??

hello rhonsman,

I feel your pain. My guess is that the flywheel is shot. Plug some words into the forum search box for some answers.

My experience was a shot flexplate (the thing that the starter engages with), and I used a big socket on the crankshaft & a flashlight to verify it.

Karl

thanks coach. i hope the flywheel isnt shot. may have to take the van to mechanic to have it looked at. what did new flywheel run you?

It's official name is a "flex plate". The first time it cost $560. This included some transmission maintenance & replacing rear engine seal etc. Second time, just to replace the flex plate cost me $300.

I would consider taking the starter back and getting another one.
The old one did not make the Ugly sound? So what has changed other then the starter motor? Fords don't need shims to install starters unlike Chevies!
I was told by a counter guy once that one in 10,000 parts is bad from the start! I seem to be Mr,10,000 way too much sometimes!
Make sure all your bolts on the engine to Trans are tight just to be safe.