Billy, thanks for adjusting the pictures.
>>>I asked the dealer if he'd seen this before and he said it happens quite often and described it as one their weaknesses. ( not sure if he meant a weakness of Ariens in particular, or a weakness of the Tecumseh starters)
There are bazillions of snowblowers with starters so seeing failures would be expected. I had about 150 used machines and I can’t say Tecumseh has a problem with mounting starters. There have been a few with cracks or a chunk has fallen off at one of the mount holes. Some have stripped holes but no telling if it was a customer mount or not. Generally I see those problems in older machines over 15 years old. For newer machines that have not been replaced by a user I’ve never seen a starter mount issue.
Possibly yours did not get screwed in fully and eventually vibrated to the condition it’s in. Pro come stock with electric start so should have been mounted by Tecumseh and inspected by Ariens. The likely problem was not having the bolts tightened down enough. It could have been the starter maker had a defective mount leg like a crack and no one noticed. Ariens sells many machines so problems expected. No flood or starter problem have shown up on the net that I’ve seen.
I’ve had bunches of that style Ariens lever mount and never had a problem. I’ve had 5 11.5 28’s and no issues. I currently have an 11.5 28 that was used commercially for 4-5 years in excellent shape except for a blown motor. After changing oil the owner did not screw in the drain plug fully, the oil leaked out and he did not notice it.
Is that the picture with the rusted section and nut the cowling issue? That’s the heater box. That’s mounted with a screw on the top, one the shown nut and two small screws on the side. With the two small screws in that thing should have almost no vibration so I can’t see how it would crack. So may be it’s not the issue but I’m not sure. Does it have it’s two screws in place? With those there is no way the heater box should develop a crack.
>>>The engagement levers are flimsy and that's why they break.
Weird place for metal to crack and I’ve never seen an issue with Ariens levers. Never saw a problem on the net about levers. I don’t see how under normal force enough pressure could be applied to crack that metal even if it was half as thin. It’s only resistance is a spring. For a lever to crack there something is unusual. Possibly the cable/belt tension was so high much more force was required than overcoming the spring tension. For regular operation I don’t see how the lever metal is under spec’ed.
>>To me it makes a lot of sense for the manufacturer to have quality control over every part of the machine they are producing.
The above was in reference to engines. Makers order engines and have some leeway for quality. They can spec builds to Teccumseh for beefier or flimsier parts to offset cost. Craftsman, Sears, Murray, MTD were usually on the reduce cost side and Ariens on the add side.
I have not seen anywhere on the net or with machines here any problems like your have had. Some of what you have is Tecumseh related not Ariens. For the Ariens issues, if they were real issues common to many machines it would show up and it has not.
BTW: Once the starter had fallen off the chances of mount hole damage are very high. If you mounted the starter did you check the holes, use loctite or something to keep the screws in?