I’m curious if any of you have ever experienced an issue with starter gear to flywheel teeth clearance, after rebuild / R&R of the PSRU????

I pulled my engine + redrive,  reworked the engine with new o-rings/gaskets, apex seals/springs; and reinstalled only to find my starter gear will not engage, and the gear hits the flywheel.  This was in a hole that I drilled to move the starter higher, but it worked okay prior to tear down from that location.  

I therefore just dropped the starter down to the hole that the PSRU came with (from Rusty :) ), and now the gears will mesh, but the gears are impinged (tight), so that they will not re-tract once power is removed, and it takes some effort with a small slot screw driver and hammer to tap the starter gear back into the housing.  

I don’t see how the flywheel ring gear could move at all to cause this issue, nor can I see how the PSRU can move at all to cause any impingement, so any thoughts / experiences you’ve seen would be appreciated!  

Doug

Photo shows original starter hole, and the one I added.  Top will now not work at all, while the bottom allows gear engagement, but sticks…

Doug