lots of starter breaks

[cardot33]

Background:I'm trying to get rid of my 90 Eagle Talon TSI (AWD) I can't count on it to be fixed for 5 minutes without some new problem rearing it's ugly head. So after about 100 miles, $2000, and a ton of headaches, and 6 months it's got to go. I was curious to see if my head gasket was blown or if it was my turbo, or oil cooler, or whatever(coolant + oil= yea its mixing now). I can't do a compression test with a broken starter though. unless I turn the engine by hand of course, but I'd like some input on my starter problem too.

Note: I put in a rebuilt transmission and a new ACT unsprung clutch recently so the car was stored inside for the winter months waiting for the transmission. The flywheel teeth were inspected by the machinist who resurfaced it and they were deemed to be in good condition. (the transmission is now painted. if that makes any difference.

Problem:I've had starter problems lately, they just break without warning. every one will turn over perfectly, the car starts up, everything's good. then try to start it on day and it's somehow broken. depending on what broke, sometimes it grinds, sometimes it just makes a whining noise. I'm on starter #4, and finally something broke in the same place twice. every starter has broken in different spots until this one.
#1-grinding-one of the long bolts that hold starter components to aluminum body were stripped out causing bad alignment of the internal gears (lasted about a dozen starts and a couple months of storage)
#2-electric whining noise-solenoid fell apart on me, the bolts that hold it on somehow loosened their way off and I was -1 starter (lasted about 1 week or about a dozen starts)
#3-grinding-there are 2 threaded holes that the bolts go through to hold the starter in place. the aluminum that made up a sort of "ear" for the threads broke off. all empoyees at the parts store agreed there was no thread damage whatsoever. (lasted 1 start or 1 day).
#4-grinding-a similar break to #3, the ear has a crack in it. it's even the same ear as #3(the higher one).

it's a lot to read, but detailed questions yield detailed answers right? what's going on with my car?

 

[belalerede]

I had this same problem with an alternator. Turns out The parts store just fixes what is broken paints them and sells them as rebuilt. In other words you get a junkyard starter for a high price. Try buying a new starter and not a reman. that is what I ended up doing.

 

[ReYnd]

There's a piece of metal that goes between the transmission and block, commonly called the starter plate. It has a circular cutout that the starter goes through when it's bolted to the transmission. That provides a lot more support for the starter than just the two bolts.

Without the plate, it's aluminum to aluminum as well, so something's bound to break. Just be glad it wasn't the bell housing. The starter is pretty heavy just to be held on by that little bit.

The starter plate is about 1/8" thick, so it acts as a spacer. All sorts of bad stuff can happen if it's not there. Mine still has washers shimming it out to prevent that horrible grinding/squealing noise, which will be replaced when I pull the whole thing whenever I can get some freakin' time banghead.

Check to be sure that's there first. If it's not, pull your transmission and clutch off, and stick that $20 plate in there. I'm not going to be one of those guys saying you can do without this piece. Second, get an OEM starter. No refurbs. I even bought a used one (non-refurb) that I suspect will outlast many of those.

Good luck!

Edit: This is the plate that almost always gets bent or broken when you separate the engine and transmission. A lot of people seemingly disregard it when they reassemble. It's going to cost somebody.