OK, I finally got back to trying to diagnose this problem. Found some concrete clues:
- When starting engine cold, I get this brief metallic noise just as the engine starts.
- When spinning engine without starting it, I get no noise.
- When engine is warm and I am doing short trips/stops around town, no noise.
Seems pretty clear that problem is that starter bendix gear is not disengaging quickly enough once engine starts.
I don't think I want to attempt starter removal. If I did, I might try and lube the solenoid/bendix mechanism and re-install. But if that does not work, have to R&R starter again
If I have shop do it, I will probably have recon Bosch starter installed. Then maybe work on existing starter which otherwise is working fine.
Before I go further with this, any other input?