I can't find the "DB" starter that I've read about here.. I've tried two off brand $125 jobs from my local parts supplier, same problem, the old spin and not engage cold deal. Tried the high dollar one from Ford, no difference. This morning it was around 28, it spun and didn't engage the first try, worked fine the second, and with new 950 CCA's and new cables it started faster than it does in the summer! Went to work, got in it at 3 this afternoon and it was 15 degrees. It spun and ground, spun and ground in the second try, tripped out and the third try she ground in and started. Going to eat my flexplate up if I keep this up. I need a good G.R. starter, who's got the best aftermarket one? This is an '05 6.0 if it matters.

 

Don't get the reman, get the brand new from O'rielly. Never had a problem with theirs.

 

Brand new from Napa have also worked well for me.

 

If you have tried 3 starters and a Ford OEM starter, I would think the problem does not lie with the starter.

 

Just get a 6.4 starter and never look back!

 

I broke the terminal off the solenoid when I was putting mine back on after the rebuild, and rather than replace the solenoid, I bought a new starter. I don't know what kind it is, but it blows the factory one away in cranking speed. Engine builds hpo quicker, and starts quicker - I bet my average cranking time is one second... or less if that's possible.
All it says on my invoice from my local auto parts store is WAI 667ON STR-FD OSGR. It was 185 bucks, and I love it!
Next time I'm out in the shop I'll look and see if I kept the box it came in.

 

http://www.dbelectrical.com/p-11999-...60l-03-10.aspx

I used their starter before for my 6.9l diesel and it was great. It cranked faster and is still in use 5 years later.

 

So looks like I'm in the same boat here as far as needing a new starter. My '04 has 228k miles (looks like the original unit) and about once a day for the last 2-3 days I have had to get under the truck and bang on the starter & solenoid. After that, the SOB starts.
Looking at Napa's website they list 2 new starters. They are the same cost at $179 but the difference I see is "Ford Permanent Magnet Gear Reduction" or "Ford Offset Gear Reduction". That sounds like two different parts that may not be interchangeable. Is that correct? If so, I assume that I need to pull my starter to see what I have.

Also, as far as using the 6.4L starter... havent seen a lot on that yet. Is that a direct replacement? No messing around? No adverse effects?

Thanks for all the good info!

 

That is correct.

 

Which ever starter you go with....make sure you LOCTITE the starter bolts real good else the starter might fall out like my stock, never replaced one did!

 

I haven't looked at it that closely, but I think the factory starter is direct drive (no gear reduction). The permanent magnet motors will make similar power (or better) as the factory starter and be smaller in diameter than one with DC powered field magnets, considering the higher rpm and the gear reduction. The offset unit is probably for specific applications where space is at a premium, likely not what you want.

I have ran Tilton "Super Starters" on a few high horsepower engines. Gear reduction and permanent magnet motor were key features. Not sure if they sell one for the 6.0.

 

Despite what some sellers will tell you, with or without an adapter plate, the 9051 won't work on a 6.0. I've got one that's got to go back. Two different starters installed, still same problem. Voltage drop checks less than .4, all cable replaced. I'm ready to pull my hair out.

 

If those are permenant magnet starters, banging them with a hammer is not real good. You break one of the magnets the starter is shot. I just can't remember if the 6.0 is or not.
In the 80's 90's Ford started putting them on just about everything.

 

Look for the problem somewhere else.

 

After as many starters as you say you've tried it sounds more like a wiring (voltage drop) problem or worse yet....the ring gear itself is already chewed up. I just don't believe it's possible to have that many 'new' starters be bad off the shelf. As mentioned in some of the other replies, look else where...jmho