Noisy rebuilt starter

[Paul Workman]

In your shoes, I'd measure the length of the rebuild (plunger) pin, take a photo of the entire armature piece, and go back to the rebuilder, explain (and show) the problem, and see if they can come up with another armature. IIRC, my OE plunger pin was ~ 3/16" longer that the one in the kit I used (mainly to refresh those copper "L" contacts) that resulted in intermittent starter issues).

I sourced my rebuild kit from NAPA, but there are a ton of Denso starters out there (Japanese cars, and even domestics [like our Corvettes] used the Denso starter. Not hard to find a source. But, must be careful to get the right one.)

Failing attempts to find an armature with a longer pin, I'd be considering fabricating a pin using a piece of drill rod, available on-line or possibly from a machine shop supplier or Brownell's (is where I get my drill rods for various projects).