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My AutoZone starter sounds like a buzz saw spinning down after each start. Shims added or removed have no effect.
I'm thinking of a MINI starter ....... has anyone switched to a mini?
I had just recently added headers and made the swap to a mini starter for clearance. I originally installed a Powermaster 9100 that works for either 153 or 168 tooth starter ring gear but I experienced a defect with it that rendered it inoperable. I have since installed Powermaster 9200 that works really well with my 168 tooth starter ring gear.
I don't know what a buzz saw sounds like so can't really get an idea from your description what is happening. but is the gear retracting after it starts or staying engaged with the flywheel?
you could pull the starter and see if it was rebuilt correctly, you said autozone, I guess you aren't aware you don't buy anything electrical there, starters, alternators, etc. are always a gamble.
as for mini-starters, do a search. hundreds of posts on guys switching to those. be careful, there are bad Chinese made mini-starters out there too...