Pinion Gear to Flexplate Issue(s?)

I have a new 350 GM Vortec connected to a remanfactured GM 350 TH. I installed the appropriate flexplate (no it not's backwards), seated the torque converter, installed a new Summit mini starter and installed the combo in my 27 RPU. Today, I finished wiring the car with a Painless wiring harness (went in very smoothly-thank you). When I attempted to turn over the engine the starter just whined and would not engage. I crawled under the car and discovered the pinion gear was a full quarter inch (.25") away from the flexplate. This distance is far greater than the tolerances outlined in the Summit instructions. I also determined the pinion gear does not extend out when the starter is cranked. I can make the pinion engage the flexplate with a screw driver and it will turn over the engine, however it then retracts and just spins without any further engagement. I need some guidance....Is the starter faulty, wrong flexplate or other issues. Any help or suggestions would be greatly appreciated.

Wrong dia. flywheel? There are two sizes,might be the wrong one.Brian

Oldmanb, Thx for your reply. The flexplate is a 153 cog count and lines up perfectly with the starter pinion. The starter (according to Summit) will fit either a 153 or 168 flexplate. The problem is getting the pinion gear to engage with the flexplate and turn the engine over. Is there a way to shim the pinion gear out from it's relaxed position to get in closer the the flexplate? I am beginning to think I have a faulty starter....

Not sure about yours but the older chevys had a starter solinoid on the starter. The current would go through it and make the starter turn. It would also make the starter gear extend to the flex plate to turn over the engine. Sounds like the starter solinoid is not working correctly. Is the spring in the solinoid to extend the starter gear?

Or the starter is not wired correctly.

Try lubricating the starter shaft where the pinion slides, either its a bit sticky or the solenoid is not pulling the pinion forward.

I went through exactly the same thing with the same motor and a Powermaster 9000 mini starter. I had to shim and reshim it to get it the proper distance from the flexplate and even after that it just never worked right. Finally, after a year of screwing around with it I tossed it into the garbage can and bought a regular full size Chevy starter and had no more problems. IMO those mini starters stink.

During that year I had numerous conversations with Powermaster and they couldn't come up with any solutions. My pinion would only travel forward about a quarter inch but the new full sized one popped way out like a starter should.

Summit is good about taking things back, I suggest you return it and get a good old regular starter and save yourself a lot of headaches. I was chewing up my flexplate because I was only engaging the first 1/8 inch or so, and the new one went all the way in. The regular ones are even cheaper, like $ 300 for a mini and $ 100 for the regular one.

Don

X2 what Don said - you've got a starter/bendix travel problem.

X3, sounds like a weak bendix