If the starter keeps getting the gears worn, there are 2 possibilities.
1. The starter gears are incorrect and cannot mesh properly with the flywheel ring gears. Did you confirm with the original starter the number of teeths?
2. The flywheel ring gears are damaged and is causing the starter gear to crash. YOu have refaced the flywheel so any damage would have been noticed, not likely cause.
3. The ignition switch is faulty, it is not releasing the solenoid after cranking. If the starter is still turning after the engine has started, turn the key slightly away from the crank direction after releasing the pressure.
4. The starter seat on the trans could be worn out of lateral due to the initial damaged starter and is now not aligned when installed.
Thursday, July 17th, 2008 AT 8:33 AM