Hey guys i need your help. Im done with my build but i cant seem to figure out why this starter keeps binding up. A little background is its a 95 240sx with a l33 aluminum block 5.3 with a Borg Warner S475 bolted to a Powerglide. Im using a 4l80e flywheel and a ptc converter. I started with a 5.7 starter and when id try to start it it would make an awful clunking noise like the starter was smacking the flywheel. Then i tried a 5.3 starter thinking it was different. Still the same result. Then i read up some more and saw that maybe i was suppose to be using a 6.0 starter with this flywheel due to the factory spacer. So i tried it and it work about 7 times with no issues while testing a couple things since it was my first start up since the build. Well i went to start it a couple hours later after i finished buttoning up a few things on the car and CLUNK! I tried it one more time and it clunked again. I looked under the car and it had actually broke the snout off the starter??? I also noticed it started a hairline crack where it bolts on to on the block. Im going to get the crack welded up before i try it again but i wanted to know if anyone could help me out with this. I have a new 6.0 starter ready to put in after i get the crack welded. Any help would be great guys!

 

And before anyone asks I have researched like crazy! Some other people kind of had the same issue but they never really got any good response nor did they figure out the issue really.