Either the vertical clearance or the horizontal engagement depth aren't optimal or there is some other mechanical or electrical issue going on here.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..
Aren't all teeth standard, so if the end gap is right, the side gap will always be the same??
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.Can you post a pic of the damage?