I own an 04 Ford E350 6.0 diesel automatic, 200 thousand miles. I've replaced the starter 3 times per a local mechanic being that the starter won't disengage. Yet, with each starter I've replaced in secession the same problem persist. I can't figure out where the problem lies to repair the issue.
There’s only three possible scenarios here that come to mind.
1. Those motors take a lot of power to turn over. Somethings just are good remanufactured. If you have indeed been getting rebuilt units I recommend getting a new one instead. Most places supply and install rebuilt ones. You gotta search for a new one.
2. If that isn’t the issue I have seen teeth on the flywheel have burs and catch the flywheel gear and not let go of it. If you have the problem with a new starter then pull the inspection plate and examine your teeth, look for chips, slightly bent or damaged teeth. You should be able clean them up with a wire wheel.
3. Some starters may have washers/spacers/shims between them and the block. If the first guy swapping it didn’t put them back on then the starter will insert to far and bind. It could just need to be shimmed.
Of top my head Im not sure what shims your starter would need. But here’s what I’m talkimg about.
