Zap - I had a simialr problem that went on for a looong time and a lot of $$$. After many starters/flywheels, we pulled the engine, took it to the machine shop who buith the brute and he finally mic'd the engagement and modified the starter case 40/1000's and documented it for me so that if it ever broke I caould repeat the process. Theories aboud as to why this happened - bad line bore (nope), bad block (possibly but it was a new Dart Big M block), bad crank (possibly, but the thing balanced out ok and ran smooth at high r's). To this day I really don't care what it was, but I don't talk to the idiots who charged me 'not' to fix the problem...
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