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I want to thank so many of you for offering up advice and sound counsel. I'm not ashamed to admit I didn't sleep at all last night.....all I could think about was the truck.
Here's what I added to the "Better Starters" thread. "I've done A LOT of research on starters over the past four days, including reviewing this thread. I spoke with Nations, Larry B, Brian from BTS and Clay from RiffRaff today. The two Denso starters mentioned above have only the name and housing in common. The internals are completely different quality wise. Larry B's is a genuine Denso; Nations is an aftermarket. I tried to find a Bosch; I looked at NAPA's along with several other chain parts stores. Please note, I'm not knocking aftermarket starters here.
I also spoke with Paul at Mean Green, their 7.3 Powerstroke starter is a 5.0 KW and has a two year warranty and lists for $399.00. Even better, they're near Pittsburgh PA, my hometown. We're planning on visiting later this week. This starter has a unique adjustable flange to allow for changing bolt-up location, i.e. the starter rotates in 20 degree increments. I would have definitely purchased this starter, but not knowing what was wrong with my truck was driving me crazy, I had to get her running.
I paid $314.00 for a new updated Motorcraft Visteon starter; it has USA on the sticker. I had to file my truck's starter cable terminal slightly. All I can say is WOW! Truck has sat for a week in cold temps (single digits including zero, and it's in the 20's today); after I installed the starter, she fired up in less than two seconds. Oh Ya! I'm glad I went OEM on this one."
Again, I have to say I'm glad I eventually went with the upgraded OEM. My cold soaked truck fired right up in less than two seconds after I installed the new starter. There's definitely a difference in the speed and power of the new starter, compared to my old factory original. Voltmeter is also reading higher now. I amazed at how insidious the power drain of the old starter was; one day it worked, the next day DEAD. I love this site!
Glad to hear it was so simple! If I have learned anything recently, it is that I will always go OEM on important things like starters, alternators and brakes! I have been punished by saving bucks through Napa and CarQuest.
Good to hear. You should update your original thread, if you have not already done so.
That's what I intended this thread for.....I was on the fence as to how to let everyone know what ultimately fixed my problem. I'll follow your advice and update original thread as well.