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Does the newer AOD transmission have a boss in the bell housing that the nose of the starter seats into?
I'm using a 1995 style mini starter in my 86 AOD.
When I started the car today the nose piece of the starter broke off.
Here is a picture of the starter and the broken casting nose piece
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There is no seat in the bell housing. That usually happens when the starter is engaged with the engine running.
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I always mount the starter before the tranny just to check clearence and engagement of the pinion and ring gear on flywheel. I have had the same thing when the starter pinoin was too tight in the ring gear when the thing engaged. A little file work to get the engagement smooth and the release smooth should fix things. By the way, those are the best starters! I get originals at the scrap yard and have never had one fail.
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I never have engaged the starter when the eingine was running, touch wood! I did a mock up with the the tranny and engine with all the accessories before installation.
All of the bearings in the starter were toast so I'm thinking thats what led to its demise, it was about ten years old. Either that or the bendix stuck and was spun by the ring gear when I tried to start it.
The new on is on and everything is kosher.
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