1993 Eurovan: I pulled the starter because of rattle sound when starting. Starter wound fine noticed the flywheel has

First off, let me address the second issue. The fuel and temp gauge is a common issue, and requires pulling the cluster and soldering some of the fittings.

There is already an EXCELLENT write up with full pictures at this site If you look through the procedure, you will see a reference to a "voltage regulator" which is the main set of pins that you will need to address. In addition to the instructions on the write-up, I would add that a forum member that I used to talk to also advised to take the voltage regulator itself and tin a little solder onto each of the tabs of the voltage regulator to make it a little "thicker" so that when you slide it into the "fingers" on the circuit board it will be a more snug fit.

As for the starter- the original design of the starter was that the "gear" was on a shaft, the end of which fit into a hole in the transmission that held a brass bushing. This hole held the shaft solid to prevent side-to-side wobbling or movement. The newer starters, rather than having this half inch shaft with a gear on it, have the ENTIRE SHAFT be the thickness of the gear- eliminating the side to side wobble.

There does seem to be a throatier sound when starting a Eurovan, almost a throat-clearing or coughing type sound it makes, very breathy if I can describe it that way. It may have a metallic scraping quality, but I've never noticed it sounding much like a "rattling".

Being 17 years old I would expect some wear at the flywheel (I'm assuming you have a manual? If so, congratulations!), and some fine metal shavings in the bellhousing. If there are burrs or something more I would be worried