2004 ( Model?) Flex plate issues- how bad is too bad?

[Kevininwa]

I recently posted about finding metal particulates on my crankshaft sensor, which I replaced in an attempt to solve a hard starting problem. It was missing and hard to start, so I ordered the part. In the following 2 weeks, it starting involved a bad metal to metal sound, so I shut it down. Changing the part did not solve it (as i knew it wouldn't), so I pulled the starter to look at the situation. The flex plate gears have definite rough edges and some wear, but they are there. At this point, I'm looking for direction about problem solving. Would it be a bad starter? It turns over but screeches as it does. And at what point is a flex plate bad? With 200k on the odometer replacing the flex plate does not make sense, and I dont want to throw good money at a new starter if I dont need to.

[firstv70volvo]

I recently posted about finding metal particulates on my crankshaft sensor, which I replaced in an attempt to solve a hard starting problem. It was missing and hard to start, so I ordered the part. In the following 2 weeks, it starting involved a bad metal to metal sound, so I shut it down. Changing the part did not solve it (as i knew it wouldn't), so I pulled the starter to look at the situation. The flex plate gears have definite rough edges and some wear, but they are there. At this point, I'm looking for direction about problem solving. Would it be a bad starter? It turns over but screeches as it does. And at what point is a flex plate bad? With 200k on the odometer replacing the flex plate does not make sense, and I dont want to throw good money at a new starter if I dont need to.

To help clarify what's going on can you provide better details of what's going on?

What do you mean missing and hard to start, was it missing after starting and that's what you're referring to? Is the starter engaging and cranking the engine over okay?
Assuming the part you ordered is the crankshaft sensor, correct?
If you didn't think replacing the crankshaft sensor would solve the problem then why did you replace it?
Did the bad metal to metal sound begin after the new crankshaft sensor was installed or was this sound occurring before the crankshaft sensor replacement? Do you have both a screeching type noise and a metal to metal sound?
Screeching noise is more of a belt slipping type noise and not a noise associated with a starter or flex plate, can you provide any more details about the noise and where it's coming from? Does the noise only occur during cranking over or does it continue when the engine starts? Does the noise sound like it's coming from the starter area?
Pictures would help and better yet a short video of the screeching sound during starting.

A flex plate is bad if the teeth are worn or chipped to the point where cranking and or engagement by the starter is affected or if the crankshaft sensor ring is damaged. The teeth and I think the sensor ring can be viewed and checked with the starter removed and engine rotated to view the entire flex plate. Is the reason you assume the flex plate is bad due to the noise or the metal particles? As others have commented the metal shavings are not typically a problem just part of the process of the starter to ring gear contact.

[oragex]

Also make sure the starter solenoid moves freely

[abscate]

Ugh. To be clear the teeth the starter engages are in the flywheel, and the flex plate bolts to the flywheel

I recall there was an issue with medal hardness in early P2, Pete sent me a flywheel once that had problems and I vanished into my entropy of projects.

You can remove the starter and look at the teeth on the starter and see if they are damaged and also inspect the flywheel teeth through that hole, and do the same here. Post pictures of both .

It’s about 2 hour of Labour to remove and replace the starter, 12 hours for and engine/trans drop

Details on another 2004 here

viewtopic.php?f=9&t=87132&hilit=Flywheel+teeth+hardness

[jonesg]

I recently posted about finding metal particulates on my crankshaft sensor, which I replaced in an attempt to solve a hard starting problem. It was missing and hard to start, so I ordered the part. In the following 2 weeks, it starting involved a bad metal to metal sound, so I shut it down. Changing the part did not solve it (as i knew it wouldn't), so I pulled the starter to look at the situation. The flex plate gears have definite rough edges and some wear, but they are there. At this point, I'm looking for direction about problem solving. Would it be a bad starter? It turns over but screeches as it does. And at what point is a flex plate bad? With 200k on the odometer replacing the flex plate does not make sense, and I dont want to throw good money at a new starter if I dont need to.

the starter gear can get worn to where it doesn't disengage after the engine fires up and that can make a screeching grinding noise.
It can also be caused by a worn out stuck ignition switch that doesn't retract back to pos II when released.

[vtl]

USA-made new starter is like $68, it is not a rebuilt Bosch with paint sprayed over rust. The replacement time is one hour maybe.