Everything is ready to fire up on the car, but the damn starter just wont line up properly. I have tried up to 5 shims to no avail. Its a 94 with a new motor and M6 FYI. I turn and key and get a click. I can go down there and look, and the gear is still engaged to the flywheel, and stays that way until loosen the starter, at which point it will retract back into the starter housing. So I am sure its not lined up right. I had no problems with the old starter when I took the motor out, so this is completely confusing me. Not to mention, the new motor is in the car and ready to roll and this is the only thing holding me up now. Please help!

 

You might want to check the charge on the battery. I had this problem with a motor and I tried shimming it and come to figure out it was the battery not having enough charge and it clicked everytime i tried to turn it over. If you have a lt1 starter and block you shouldn't have to shim it at all.

 

Check for voltage at the starter while cranking. The pinion can get jammed in the flywheel due to improper/inconsistent voltage. This seems a lot more likely than an LT4 starter not fitting correctly. Good luck!

 

Got the right flywheel?

 

mine bolted right in ........

 

Factory resurfaced flywheel.