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...what can happen to cause this
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It's not all that unusual over a long period of time. It has nothing to do with faulty starter or bendix operation. Engines generally stop at the same crankshaft position on shutdown so a certain small number of flywheel teeth get all the wear and tear. It's been a long time since I've done surgery on one of those (retirement's great
), but if I remember right, they're like all the rest. After you pull the flywheel, you make a notch between two ring gear teeth with a chisel to expand it and then it will slip right off the flywheel. Then the new ring gear has to be heated with a torch to expand it, then you pick it up real quick-like with a couple pairs of pliers and drop it onto the flywheel. You DON'T want to overheat it or you'll soften the steel. It's fairly common to have to replace the flywheel ring gear on any big Cummins, Detroit, etc, during an out of frame engine overhaul.
