The problem is occurring because you are playing in the greyest area of a powertrain claim.
The dual mass flywheel, the pressure plate, and the throwout bearing are covered if they fail.
The clutch disc, a wear item like brake pads, is not a covered repair unless it has experienced a mechanical failure....that being the anti vibration springs and slip face area.
You are seeing, (or somebody saw) clutch material building up on the starter shaft......leading to the ASSUMPTION that there may be the possibility of a non covered part failure.
OK....hold that thought......lets see if your definition of grinding and a mechanics definition (me) of grinding, in this situation are the same.
To me, the complaint 'grinding while starting' is interpreted as: There is a loud, grinding sound that occurs when the key is turned, at a startup attempt, the engine does NOT start, and the grinding stops when the key is released.
A second or third attempt at starting the engine will result in a normal starter engagement and the engine starts as expected.
Read my interpretation a couple of times, slowly....................does this accurately describe what you have been trying to get resolved?
If it is, inspection should reveal damage to the starter pinion gear as well as the flywheel gear teeth.
For the record, having spun wrenches for over fifty years, I have never seen clutch material restrict starter pinion travel.....I suppose you could be the first, but I have my doubts.
If there is no damage to the flywheel teeth, then a starter replacement would be the first step (we are trying to resolve a grind, remember, the dealer mechanic has brought up the clutch thought).
That starter, BTW, is to be installed with the mindset it is for testing purposes.......to support the mechanics diagnosis.
In the event the problem is gone, the mechanics suggestion of a obstructed pinion now has merit......the starter stays installed and everybody stops talking about a clutch.
Back to the 'who pays' clutch discussion.
Because of the possibility of a non covered, wear item failure presents itself, the dealer has to prepare you for possible expenses that will be on your dime.
You are being warned of this possibility prior to disassembly for a good reason.........if you are a normal person, you would go ballistic if the car was disassembled and THEN they told you it will be at your expense and, Oh by the way, you have already incurred $XXXX and your car is all over the floor.
In the event a covered component has caused excessive friction disc wear, then the entire costs can be directed to Chevrolet as a warranty claim.
If you have other questions, or determine that your failure description may be causing confusion, post back.
I'll watch for your response.
Rob
