When i hit the starter & the pinon gear engages it will not spin the flywheel. Sometimes it does, but it is not consistent. Had the starter apart & all the gears look good. The clutch in there turns hard. I sprayed it with teflon oil & that helped. Checked the battery[new] & its fine, 12.8 volts. Do not have a load tester. Any help would be appreciated. Jon M Riley

 

Sounds like the starter drive or overrunning clutch, whichever name you prefer to call it.

The starter will engage, spin, but wil not turn the engine over because the starter clutch is slipping.

 

my 98 makes a clunking sound 1 out of 10 times and it sounds like metal hitting metal. I too can't figure it out.

 

End play in the armature, the drive engages too far and contacts the ring. It is a simple fix to shim the drive end of the armature to keep it from hitting the ring.

 

sounds like a bad starter clutch to me.

I've replaced many. Once the sprag in the clutch gets weak, it's toast. Usually happens after a "kick back" when starting.

 

Check for a voltage drop between the battery and starter connection.. a bad or weak ground could cause the problems also... The battery could be new and check good but if there is a weak connection there is a lack of cranking juice getting to the starter it will effect it's operation.

 

Replace the starter drive.