Figure this one out...

[J-440]

So I take off my starter to install a 4gauge wire from my alternator to the big terminal. Rebolt it back up, turn the key and the starter gear just spins freely. I unbolt the starter, have my wife turn the key while I'm looking at it, the gear pops out and spins, then retracts. Ok cool. I bolt it back up, turn the key and the gear spins and does not engage the converter teeth. What the hell is going on? This thing worked perfect before I took it off and now this happens. Any ideas or do I need to find a priest?

[bovey]

The only thing different is the fact the starter is touching the block - and that seems to be affecting the solenoid - I know - stating the obvious. Maybe check all the connections on your solenoid - make sure they are tight - especially the ground wires. Sounds to me like the solenoid electricity is getting confused when you install it. When you have the starter off and it's working try moving the wires around - broken wire maybe - wear gloves for this exercise.

[ccmc]

Did you drop some shims? Look under the car where you pulled the starter for some shims. They are used to move the starter gear closer to/away from the flywheel

[J-440]

Good points but there were no shims and the car acted fine before I took the starter off. I'm gonna rotate the flywheel a turn or two then try again. Hope this works because I'm at a loss.

[J-440]

Ok, I'm about to shoot my car. How in the world can my starter gear not be contacting the flywheel after I add a thicker gauge alternator wire to the starter? All the wires are good, the starter gear/solenoid is functioning, all the teeth on the gear and flywheel are excellent, I added/removed shims, and I even turned the motor with a cheater bar. Still no contact though. Any thoughts?

[J-440]

I'll answer my own question in case anyone has the same problem. Apparently the wires on each terminal aren't supposed to make contact. Well mine did and I got a nice orange flash in my face. So after taking the starter off one more time and then taking it apart, I was then greeted by some black powder inside the case. Think I found my problem.