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starter chipping away fly wheel 900

The starter of my 93 940 is chipping away small flakes of metal off the fly wheel. The starter is not damaged. Could be metal fatigue on the 20 year old car?








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    starter chipping away fly wheel 900

    I am just wondering now what will be the result of replacing the starter on a damaged ring gear. I don't think this will solve the problem. Do you think I need to replace the fly wheel also?








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      starter chipping away fly wheel 900

      Dear Volvito,

      Hope you're well. Unless the ring gear has been heavily damaged, a starter change will restore smooth operation.

      On an '75 245, an improperly-made starter drive gear (wrong angle, made by Bosch) slightly damaged the ring gear. Volvo eventually agreed to replace the starter drive. Thereafter, all was well.

      You can inspect the ring gear's teeth through an access port, that is also used to wedge the ring gear, in order to replace the crank pulley (if one does not have the counter-hold tool or want to use lucid's "rope trick"). See the FAQs for how to access this area.

      If entire teeth are missing from the ring gear, it may need to be replaced. I doubt that's so. More likely the starter drive's gear "shaved" some metal from the side of each ring gear tooth, facing the starter. I doubt very much metal has been removed.

      Hope this helps.

      Yours faithfully,

      Spook








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        starter chipping away fly wheel 900

        OK spook
        Will go for a new starter and hope no additional damage occurs. The chippings are small facing the starter. I have modified the crank sensor with epoxy glue so the end of the magnet is flashed. This may minimize the collection of metal in the future and hoping that if it does is sweep away rather than jamming and damaging the sensor. So far the modification have not affected driving. so it may be the ticket. What do you think of a little silicon grease on the ring gear?








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          starter chipping away fly wheel 900

          Dear Volvito,

          Hope you're well. Thank you for confirming that only small chips have been removed from the ring gear's teeth. A prompt change of starter will contain the damage. A new or re-built starter will not add to the problem, so all will be well. That is, there won't be any metal dust/chips/shavings to interfere with the crank sensor's smooth operation.

          I presume you put the epoxy around the sides of the sensor's metal tip, without covering the flat face of the metal tip. If so, the epozy shouldn't affect the sensor's ability "to read" the openings in the tone wheel, that is attached to the ring gear.

          You might put a little white lithium grease on the starter's pinion, before you install it. That grease will soon be spread evenly on the working surfaces of the ring gear's teeth.

          Hope this helps.

          Yours faithfully,

          Spook








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            starter chipping away fly wheel 900

            Yes, the epoxy is around the metal tip of the sensor. Work very well. Lithium grease sound like better choice. New starter coming tomorrow. Not a Bosch, but at least lifetime warranty. It should be fine.








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    starter chipping away fly wheel 900

    OK. If the starter gear will not show damage, but still can be malfunctioning that may the the cause of the damage to ring. No bad noises that I can tell. The starter is the original Bosch. never replaced before. The reason I found the damage to the ring was a broken crank sensor. The chips of metal were sticking to he sensor magnet. Then came the ring turning and when enough metal build up it would hit the magnet damaging the sensor until it broke.








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    starter chipping away fly wheel 900

    Dear volvito,

    Hope you're well. If you're sure the starter is the source of this damage, then the starter is malfunctioning and needs to be replaced or re-built.

    When the engine starts to turn under its own power, the starter's drive gear is supposed to retract, so that it cannot contact the ring gear's teeth.

    If the starter drive gear does not retract quickly and fully, it grazes the ring gear's teeth. That damages the ring gear. The contact may be slight. But the damage is done. You should hear some unusual noise, at the instant the starter's drive gear touches the ring gear's teeth.

    To avoid having to pull the transmission, to replace the ring gear, I'd replace the starter or have a shop re-build the in-service starter.

    Hope this helps.

    Yours faithfully,

    Spook








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      starter chipping away fly wheel 900

      What Spook wrote----the ring gear will show damage long before the starter gear. BTW--you probably have the later small starter. If it makes any difference (availability) the old, larger type will fit right in. -- Dave







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