Phil Thompson

<center><img src="http://pictureposter.audiworld.com/59720/p1060288.jpg%20,http://pictureposter.audiworld.com/59720/p1060279.jpg"></center><p>(4.2 Quattro) When my starter motor engaged there was a big bang which sounded like a backfire. The engine didn't start so I tried again. The starter was sluggish but started the engine followed by noises indicating all was not well in the starter department. The noises disappeared so I drove 10 miles home. I have removed the starter and found that the drive end bearing housing has been broken off (new brittle fracture - see photo and the broken bits have disappeared into the starter ring/torque converter. The broken casting appears to be made of aluminum and does not appear to have done any significant damage to the starter ring and torque converter. I have examined the starter ring teeth and attach a photo of the most damaged/worn (the fresh scratches were made by my screwdriver turning the engine). I am attributing the failure to worn drive pinion teeth trying to jump a tooth. My dilemma is what about the broken bit(s)that disappeared into the starter ring/torque converter area. I don't fancy removing the transmission to remove them, but dare I leave them, bearing in mind they have been in there for 10 miles already? Has anyone else experienced this problem or am I the first again?

gondar

Your pic won't come up for me (heavy firewalls)so I don't know how big the bits are. Usually the whole nose cracks but sort of stays put. You might consult with a couple of starter rebuilders and see if they have an opinion.

It sounds sort of draconian but you could perhaps drill or grind a small inspection and removal hole in the bellhousing. The patch it. If a piece gets jiggled up into the ring gear you may have one from the inside out.

Another possibility would be inject a small quantity of liquid epoxy, in the bottom, tie the bits down. Don't glue the tranny to the block!

Neither of these is the "right" way, needless to say.