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For the first time ever, the starter gear clashed with the flywheel ring gear when starting my 1940 160, causing a grinding noise and resulting in damage to both gears. I have never had this happen before and am wondering what happened here. Could the starter have failed to disengage? Was it metal fatigue when the starter was engaging with the ring gear? We're trying to diagnose this to get to the root of the problem and any thoughts are welcome. Thanks!

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For whatever reason, starter pinion did not engage flywheel ring gear teeth. Could be weak solenoid. Could be there was already worn gear teeth on flywheel or starter pinion or both. I've changed a lot of ring gears over the past 48 years, and, Unfortunately, you're going to buy parts. Have that starter rebuilt or at least replace the pinion and solenoid, and load test battery and check electrical connections. PB

Another possibility:
The starters spin throws the gear down the pinion axle to engage the flywheel.
If there is dirt and lack of lube on the bendix axle the gear will not move all the way down and cause gear clash. (the 1st 84 years is always the hardest!)
When you get the starter rebuilt this area will be addressed too so it will not happen again.
Mine had that issue before rebuild, along with a host of other things, what is it one guy said, more Issues than Sports Illustrated!
Bob J.

Thank you for the quick responses. Once again, the parts buying process has been initiated!