My starter woes continue. My original starter went out last year with heat sink issues, I had it rebuilt and had the same problem the very next day, had it rebuilt with "heavy duty parts" that lasted 1 week, then same issues. I was so mad I said scew it and bought a high torque mini starter. That made a small gringing sound. Tried shimming with different sizes with no avail. Then today it made a horrible sound like all the teeth were almost stripped off the flywheel, took the cover off and the starter out, the edges of the flywheel are very lightly chipped (not bad), so are the teeth on the starter. It looks like the starter was only making contact with about 1/8" of the flywheel. What's up with that? Shouldn't they be engaging each other at least 50%? I think I'm going to take the original starter to a better shop, this has been a big pain in the butt!

Get yourself a Mini Starter and end your heat sink probs once and for all.

 I've got mine in the garage getting ready to put it in...my bad arm is too sore right now from all the steering work I did (against the judgement of my doc)...   Personally, I call the pain part of the proce of owning one...she didn't understand it though...

If you had shims under the starter, remove them.  If not the starter may be made for a different application.  Check for paint or other build up on the mounting surfaces.