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In my LSA project I added cam, lifters, chain, Oil Pump - All the Fix'ns to the bone stock 50K mi LS6. Part of this includes a new Bosch starter - 2 long bolts vs 1 long-1 short (pic is attached). After I did all the internals I used the OLD starter to spin the engine A LOT to build oil pressure. There are no spark plugs of FEAD belt so it spun it FAST & Smooth. It seemed to work.
Fast forward - I installed the new starter and my entire exhaust- but like a Dummy, did not test the brand new starter before installing the LT's and pipes. It is making a HORRIBLE sound and spins slow & labored - still no plugs or belt. Take a look at the IMGUR link for a video of this ugly, nasty sound. I did notice that the new starter's drive gear was 'taller' - sticks up higher in the cup. That's the only difference - other than dirt - that I saw at a glance. It's BRAND NEW and supposed to act brand new..
What might be causing this? It will be HOURS of work to get the starter back off. Also have a brand new Optima Yellow Top.
Any help would be, well, helpful. I am at a loss.
I know its not tradition, but it is possible (though heresy) shim the starter BEFORE installing the engine back in the car!
Like every flexplate ever yours isn't perfectly round, and the tight sections are what I believe is making that sound. You need to put a shim between the starter and the block to shim it down a bit.
Thanks for the replies - I already took it out and to a shop (local GOOD Auto Electric), He's gonna 'go over it'. I'll make a decision then.
What's the story on truck starters for LS1 / 6? If I have to replace it - because it has a PD Blower - should I look into one of them? Or just have the OEM 50K starter 'gone over' and put it back on?
I keep taking one step forward and 2 steps sideways. How unusual for me
Thanks again for the help!
Sounds to me like its in need of starter shims. As Kawboom said, not all flexplates are perfectly round and not all casting and machining is perfect for aftermarket parts. Luckily this shold be a relatively easy fix. Well, easy on the wallet maybe not on time
Take your OEM ("old" ) starter to the starter repair shop, have them inspect and repair as necessary.
Probably just need solenoid contacts, and blow brush dust out.
I have never seen nor heard of an LS starter requiring shims to mount and mesh correctly.
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New Starter - UGLY noise - HELP!! 
