You mentioned the bolts were mismatched? I don't see how it could be so if both starters are exactly the same.
If the original starter has the correct reach, I see no reason why the new one should have any problem.
Ground the starter housing and apply battery voltage to the solenoid to see if the pinion gear is moving out fully. There is a possibility the starter pinion is not moving out fully due to the solenoid movement.
Saturday, September 29th, 2012 AT 8:36 PM