Originally Posted by ryker
Took the Rav to the dealer and they did an entire diagnostic check and pulled the starter. Found nothing wrong and of course couldn't replicate the sound.
Not more than 10 minutes later when I got the car back, the car made the sound again right when starting up.
So... now what? Video tape the sound if I can catch it?
If it was the starter grinding, there would have been evidence of such on the flexplate teeth or the starter gear. But the techs didn't find anything?! Solenoids on starters can easily be tested, so I guess its good. I don't know what to advise you at this point.
As a long shot guess, you may have nicked a tooth on the flexplate so only when the starter engages at that one point of the flex plate's circumference is it grinding. The other times it is engaging without noise. Have you ever used the starter after the engine was already running? That might have contributed to or initiated a problem such as I described.