[ACHiPo]

I figured out the problem, now I just need to figure out how to fix it. The geometry of the new starter is correct--both starters' Bendixes extend about 1 1/8". The starter's mounting flange is correct for the bell housing, and the starter sits flat on the mounting surface.

When I hook up jumper cables to the starter, I can either get the Bendix to extend, or the motor to spin--not both, depending on where I connect. So I definitely have a problem with how I'm connecting things.

Per the instructions I jumpered the starter and battery terminal on the starter when using a remote solenoid. For the bench test I assumed I'd need to use the built-in solenoid, so I connected the battery ground to the starter frame, the positive to the battery mounting post on the starter. Hooking it up this way caused the Bendix to extend, but the starter didn't spin--I've energized the solenoid, but not the motor. Reconnecting the jumper between the ignition and battery posts on the starter, the motor spins, but no extension.

Here is the way I wired the starter in the car. On the bench I get the same behavior--the motor just spins.


I also tried connecting the ground stud to the battery ground with the same result.

(I've got photos and video, but can't link or upload them).

If I remove the jumper and connect the battery to the two studs on the starter using the internal solenoid, the Bendix actuates, but no spin.