UGH!!! Starter Issue. HELP!

Hey 67DART273, and anyone else that's electrically savy; I need your electrical wisdom!! Anyone...?

As you'll recall I originally had a minor starter wiring issue ("Mystery Wires" thread a couple weeks ago). Everyones gave good input which ultimately fix'd the wiring mess and she cranked over just fine. I'm still not at the stage to start it yet (radiator isn't installed) but getting very close.

A few days ago I decided to spin her over and check for leaks at the oil pressure tube to the gauge. The spark plugs are out, so she spun great. First spin was for approx 8 seconds, and no oil pressure. Repeated this for another 8 seconds, and still no pressure. The third time I got 64 psi within 4 seconds. I got out, checked for leaks, and all looked fine, no leaks.

I decided to do it one more time and within 2 seconds had oil pressure almost immediately...BUT then suddenly it sounded like the starter let go or disengaged (free spinning) but the key was still in the start mode..? The engine stopped spinning, but the starter was still whining.

I investigated, found nothing, and the starter was warm but not hot. Then I noticed the starter gear was still engaged with the flywheel teeth...? (Bell housing bottom dust cover is still off) So I used a screw driver and popped it loose (took no effort). Turned the ign key and again the starter just spins, but the engine doesn't turn...? Got under there again and the gear was again engaged with the flywheel teeth. I used my finger this time and it popped loose, snapping back into it''s normal dis-engaged position.

What the heck have I done...? Did the starter burn out or break just from THAT..? Just from spinning the engine over...AND with no plugs..? It's a mini starter roughly 1600 miles old and is used on Durango's / Jeep's...etc.

I jumped the starter relay with a screw driver (crossed the two big posts) and the same thing: starter spins but the engine doesn't move and that gear just stays slightly hung-up with the flywheel. Perhaps they all do that to some level, because I can't imagine it staying that way for long with that flywheel spinning and engine vibration. Just don't know.

I took the starter to a shop, they stuck it in a machine, said the starter was fine, passed all the tests AND the little gear was spinning like crazy.... so what the hell...? Why won't it do that on the engine? :-(

In order to combat the gear teeth not disengaing, "I ignorantly" ground away what material I safely could from the bolt holes and on the starter snout to allow a little slop and move the starter slightly away from the flywheel. My efforts made very little difference, it still gets hung (sort of) and doesn't spin AT ALL.

NOTHING I have done has effected the situation positively AT ALL... so I'm basically out of answers.

PLEASE someone save my sorry stupid butt... :sad3:

This must be very simple to someone reading this, so PLEASE share your wisdom.

1) Starter went bad..?.. even though the test machine said otherwise..?
2) Bad Starter Relay...?
3) Bad day...? yes!