Starter isn't engaging after clutch job

Hey all, I'm looking to see if anyone has some insight. I've got a 2007 tacoma, 2tr-fe and 5 speed. I put a new clutch in, along with swapping to a R156F transmission instead of the original R155F. All new components, resurfaced the flywheel, new rear main, along with an FJ tcase swap.

The problem is, the starter isn't engaging the flywheel now. Everything is lined up and bolted down tight. I've had exactly one time the starter actually started the truck, but then it sounded like it wasn't disengaging. I've got a new starter ordered, but is there anything else I should look at? Should I have not used the original flexplate as this transmission is off a 2016?

I'm at a loss other than replacing the starter. I took the starter off and bench tested it. All appeared to function properly, with the bendix working and no funny noises. Any help is appreciated!

 

Just a point of clarification. A 5-speed manual transmission uses a flywheel. An automatic uses a flexplate.

 

I misspoke. I'm talking about the black steel plate that goes between the bellhousing and the block.

 

No experience with 2gr, but i had to wonder if there was a shim or plate that didn’t get reinstalled with the starter. Sounds like the the starter is too close to the flywheel in its lateral position.

 

If it actually started the truck once, then the bendix is not likely too short.
Maybe it’s too long? And when the truck actually started it got stuck behind the flywheel?

I honestly don’t know?

@BassAckwards

 

I am running an R156F in my 2009 but using stock 2009 flywheel, clutch and pressure plate. Did you use the flywheel from your 2007 or out of the 2016?

 

I used the flywheel out of my 2007. I had it resurfaced, but otherwise the same as before.

 

That is an interesting starter it is gear reduction and shimmed between the starter and the block. Does it make any noise or just do nothing?

 

It makes a noise, obviously hitting(grinding) on the teeth but not engaging. Save for the one time, where it started but then didn't disengage until I shut the truck off. I did bench test it, and it functioned flawlessly.

On a possibly related note, my last offroad run when the throwout bearing left the chat, I had a Jeep "duck" me right before. Since then, nothing but troubles. I'm thinking bad Jeep MOJO. Lol

 

Sounds like starter. Maybe something binding or when you hook it up, theres enough electrical resistance/bad connection the starter isnt engaging fully.

 

Sounds like the starter to me as well. You should have no issues running your 07 flywheel.

you might pull the inspection cover on the trans and take a quick peek at the ring gear on the flywheel, but I doubt that’s the problem

 

That's what I'm thinking. I pulled the inspection cover and other than a few nicked teeth from the starter, it looked kosher. I rotated the engine by hand just to make sure something wasn't bound up, and it all moved normally. Had a friend push the truck with clutch in, and let it out which stopped the truck. So that appears to be functioning fine.

 

The starter should have shims between it and the engine they would change where the starter engages the fly wheel. Can't see it from my house and it wouldn't make a huge difference noise maybe.

 

Welp, verdict is in. The start evidently wasn't extending the bendix far enough. New starter worked, although slight noise on startup, which I attribute to two things--> the teeth being nicked from oe starter and no interior at the moment.

 

Update: back to square one.

Starter that I put in, a napa reman, has made a slight noise since install last year but never failed to start. Seems to be getting quieter lately, so I attributed it to the teeth finally wearing in from initial damage last year. Maybe 7k miles in a year a with no failures. Until today. Drove approximately 40 miles to run errands and it failed to start on my second stop. Obviously spinning, but not engaging.

I got a push from friends and started it that way. Brought home and put it in the shop. Yanked the starter and found extreme wear on the teeth, and bendix looks fubar. Contacts inside looked good minus minor arcing.

I proceeded to bolt the OEM starter on, that I had rebuilt by a local reputable shop near me last summer as a backup. Started the first hit, didn't disengage. Now won't engage to start just like last year.

I'm at a loss folks. The flywheel still looked good when I dropped the inspection cover. If I shim the starter, that only moves it further from the flywheel. Should I removed the black alignment plate between the bellhousing block?

Pics included of reman Napa unit and the local rebuild I just put in.

 

Question for you...when you did the swap, did you reuse that black alignment plate that went between the bellhousing and the block?

 

Yes I did

 

And you used the bellhousing that came with the R156F? The bellhousing off both transmissions looked the same, but maybe one is thicker.

Either way, I swapped the Napa reman for another Napa one. It worked, making the same noise. I measured from top of the bendix teeth to the mounting face of the starter. The reman was .7 mm deeper which might explain it actually engaging. I also took pics of the ring gear teeth, obviously not great shape but no broken off teeth. I've included pics of the teeth, and a short start video for the noise.

https://youtube.com/shorts/lZhwRvOczX4?si=MLwWLJorf0EaBICY

 

Yes R156F bell housing
R155 flywheel, clutch, pressure plate, and TOB
stock clutch hydraulics and OEM starter as well

 

That's exactly what I used, so I'm kinda stumped. I might just take it all apart to investigate. I must have gotten something off somewhere but I can't see anything obvious from the outside.