I've had to replace the starter in my car 7 times . Don't buy from AutoZone. Starters 1-3: Rubber Mallet. Starters 4-6: Hot Starter. The Starter in the car now is from Advanced Auto Parts and so far, no problem with it for over a year. If this one fails, i'm just going to buy one from Summit brand new.
i use the small magnetic starters for '98 and newer cars/trucks. they DO NOT have the 12v kick-up and you need to get shorter bolts. but they are lighter, stronger, don't have the same heat issues and can handle low voltage issues.
Summit sells a kit ... with everything you need ... for $20.95 That might just fix your problem. This is what the other guys are using to solve the Heat soak. Or just make one up yourself from pieces ... http://store.summitracing.com/partd...925143+4294839066+4294845013+115&autoview=sku
Please explore one last fix-it option before I have to convert to something like his Astro starter. I have a starter that bolts onto the bellhousing with 3 bolts (64 gmc manual) and everything seems to fit just fine. 168 tooth flywheel looks like teeth fully mesh. Sometimes (gotten more often over the last year, 80% lately?) the starter gear appears to hit the flywheel and spin against it instead of pushing all the way out and meshing the gears. What are some things I can try? Obviously I can't shim it radially out from the flywheel, should I try to shim it out (axially?) away from the bellhousing? Maybe file down the leading edge of the starter gear teeth to give it more slop? alan