We use the solenoid on all of them, this one is no different. The engine spins and fires, I just think it's still a bit noisy. I always use a #10 wire for the jumper on the starter solenoid - never had a power issue. Also this car has two starter buttons, one next to the ignition toggle and another on the firewall. Either one spinning the starter makes the same noise. I might have some time to look at it again tomorrow and I'll see if .035 is the trick or not.
Been really busy so haven't had a chance to check the .035 deal yet. But to answer you question I do know that there are a couple of different pinion gears both of them with the same tooth count so I couldn't really say that .035 at one point would be equal to .035 at the other. I will check that of course.
No point really, what little bit there was to the flexplate I smoothed off with a couple of passes of a fine file. The pinion on the starter has one tooth on the leading edge that has a .0001 mark on it, can't really see it without a strong light.
I had a new sfi flexplate and mini starter, once started it made a hell of a racket, turns out the ***** who made it did not have the ring gear in the right spot when it was welded, it was always slightly engaged, took out and returned, we checked against a know good one and laying flat you could see the disparagement between the too, the bad one was offset wrong.
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