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Usually it's because the clearance between the starter drive gear (pinion gear) and the flywheel ring gear is too tight. Many vehicles use shims to increase the clearance (backlash) between the two gears. Also, you did not mention the year make or model of your vehicle, but if it is a 1996 through 2000 GMC vehicle there is a technical service bulletin (00 -- 06 -- 04 -- 014) that could be the cause of your problem. If you also have a trouble code P0338 (with no check engine light while the engine is running) there is a good possibility of it being your crankshaft position sensor. If you have the above trouble code it could be that your CPK is advancing the timing during cranking, and putting excessive stress on your nose cone, ring gear, and engine block (where the starter attaches) and can break any one or all three of the above components.

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Q: Why does your nose cone keep breaking on your starter?
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