Not my truck, but I've been out in the rain working on it tonight. 1996 F250 HD with a 460 and auto. Guy said his starter was bad and wanted it replaced. Got a reman and it still does the same issue. I don't have a lot of tools with me at the moment (writing this in a parking lot) but I'm bringing it to my house tomorrow.

The issue is that the starter winds out, but the motor still won't crank over. This is the same issue it had before replacement. I jumped the solenoid on the fender, no change. Looked through the inspection plate and the starter appears to be throwing out and hitting the fly wheel, but not meshing into the ring gear. I crossed the starter I got and it's "supposed" to be correct.

Any ideas before I go chasing my tail tomorrow? Thanks.

 

It sounds like flexplate has a spot where the teeth are ground off. Turn the engine a little by hand and try the starter again.