Posted 18 December 2011 - 07:30 PM
To get the gears to mesh, some compromises have to be made. You can't have a perfectly formed 9 tooth gear, and a perfectly formed 10 tooth gear, meshing with the same ring gear, with the same centre spacing. The design of gears with such a small number of teeth has to be compromised anyway. Proper involute gears should run nearly silently, but those never will. Because it is only the starter, which is used for a few seconds at a time, that is ok. It may be just that the tooth profiles do not conform very well, plus the ring gear will have been worn to match the profile of the old gear.
If you pull the starter out, and check for obvious damage to the pinion and the ring gear, or the presence of metal particles, and none are found, it is probably nothing to worry about.
Different problem, different ring gear design, but a while back I changed a preengaged starter and the new one sounded very different to the original, although it looked much the same. Presumably just new gear running on old, because it worked well for a very long time.