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Car eats starters - baffling many 200 1993

could it be a shim problem?
The mounting pad for starters is machined on the block as is the mounting surface on the starter itself...if it was machined a little thin on either the starter or the block the pinion gear (starter gear) would engage the ring gear on the flywheel at the tooth root and cause a jam.

I've not noticed starters on volvos installed with shims, but many other cars have them to adjust the starter teeth correctly. I think they're available at most auto parts stores. You can test for tight starter teeth/ring gear by grounding out the ignition wire and spin the engine over with the starter and listen for proper engagement.

I'd put one thin shim (.010 or so to start) in between the starter and the block....







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