[Hotrodjohn71]

Let me be a bit more specific in my question as I just reread my post and it seems to leave a bit to be desired.

I'm referring to the thrust travel of the pinion gear into the flex plate ring gear when the solenoid is fully engaged.

Earlier today, I was underneath the car attempting to perform the paperclip clearance check of the pinion gear to the ring gear valley clearance (.020 - .035), and using battery power connected to the starter S terminal to engage the solenoid, I noticed that the pinion engages all the way through the ring gear plus about 1/16".

This is a Powermaster 3655 which is basicly a stock style (not mini) starter.

I see in the instructions there is a minimal clearance from pinion to ring gear when the starter is not engaged. But nothing about the fully engaged thrust travel.

The reason I am enquiring is that I've read that on Chevy starters, the pinion is only supposed to engage about 1/2 or 2/3 of the way into the ring gear.

[Kenth]

I have relegated the paper clip method to the junk box as it is extremely unpredictable for a properly functioning starter motor. Instead, I use a 1/8" Allen key that is placed between the pinion gear shaft and the starter ring. The key should just go in between but not be able to turn, then the distance will be perfect.

With worn out parts the pinion gear travel will be less than optimum, i would like to see full engagement of the gear.

FWIW