Battery Cable
I think I'm on my third NSS. The one I have in there now doesn't have many miles on it (I don't drive it much these days). But yes, it has to be on the suspect list nonetheless.
BTW, the 36" (4 gauge) power cable from battery to starter was the right length. Plenty long enough with enough slack to rework the end maybe twice if ever needed and it doesn't droop. I cable tied it to the side of the sheathing the old cable is located in. I left the old cable there. Not worth doing surgery to remove it.
This starter has a different sound. Not during the crank but kind of a brief screaming sound just as it fires up. Mopars always had a unique starting process.
BTW, the 36" (4 gauge) power cable from battery to starter was the right length. Plenty long enough with enough slack to rework the end maybe twice if ever needed and it doesn't droop. I cable tied it to the side of the sheathing the old cable is located in. I left the old cable there. Not worth doing surgery to remove it.
This starter has a different sound. Not during the crank but kind of a brief screaming sound just as it fires up. Mopars always had a unique starting process.
Trouble is, I don't think there is anything you can do about it.

Are ring gears intentionally made harder than starter gears so that the starter will fail before the ring gear? Or am I thinking too much as a consumer and not an automobile designer?

The noise may lessen over time.... or, it may get worse..... but, given how the starter mounts.... unless you want to elongate one of the holes (which could cause problems all it's own.) I think yer stuck with it.
That, I do not have an answer to, though I like your way of thinking. 
The noise may lessen over time.... or, it may get worse..... but, given how the starter mounts.... unless you want to elongate one of the holes (which could cause problems all it's own.) I think yer stuck with it.

The noise may lessen over time.... or, it may get worse..... but, given how the starter mounts.... unless you want to elongate one of the holes (which could cause problems all it's own.) I think yer stuck with it.
Not entirely sure it would matter..... its clearances between the starter gear, and ring gear that are the problem..... Might work, might not. Lotta work if it don't though..... If it isn't too annoying, I'd leave it go for a while, see what happens. If it still is doing it when you are getting toward the end of the warranty period, I would be real tempted to swap it out.
Not entirely sure it would matter..... its clearances between the starter gear, and ring gear that are the problem..... Might work, might not. Lotta work if it don't though..... If it isn't too annoying, I'd leave it go for a while, see what happens. If it still is doing it when you are getting toward the end of the warranty period, I would be real tempted to swap it out.
I’m not sure what is considered mildly bad, bad, or severely bad. You clearly have run across this before. I haven’t so I have no idea how to measure the severity. I will keep a close ear. The few times I started it the scream seemed to happen at the end of the crank just as the engine fired up. It was quite brief. I need to listen more. Maybe stick my head in the engine compartment and have the wife start it up.
Nah, If you have to work that hard to hear it, then it isn't really a problem. 
This was a common problem on the original chevy small blocks, but, they made shims for the starter, to get the clearance right. Don't get that option on the Dodges, simply due to the way the starter mounts.

This was a common problem on the original chevy small blocks, but, they made shims for the starter, to get the clearance right. Don't get that option on the Dodges, simply due to the way the starter mounts.
Nah, If you have to work that hard to hear it, then it isn't really a problem. 
This was a common problem on the original chevy small blocks, but, they made shims for the starter, to get the clearance right. Don't get that option on the Dodges, simply due to the way the starter mounts.

This was a common problem on the original chevy small blocks, but, they made shims for the starter, to get the clearance right. Don't get that option on the Dodges, simply due to the way the starter mounts.
This is where the chrysler mounting method might be superior to chevys..... no fussing with shims required. Assuming the starter motor manufacturer has decent QA.
Took the truck out and made several starts. There is definitely a scream. Doesn't happen as soon as I turn the key but rather just as the engine fires up. Could it be that's when the gears are spinning the fastest? Of course the entire starting process from key turn to engine running is a pretty quick 1 second or less so deciphering timing of noises isn't exactly easy to do.









