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Hey Gents Im having an Issue with a 6.4 starter in my 6.0. About Every 9 months im having to replace my 6.4 starter on my 6.0. i have had my truck since March of 2016 one of the first upgrades was the 6.4 starter. well all is well until 9 months down the road the 6.4 starter starts to Hang when i let go of key like bendix is getting stuck in flywheel. then it starts to grind like its has a bad spot on flywheel. when it does this i bump starter then it cranks and fires up. is this a common issue? in my attached picture starter on right is my starter that came with truck starter on left is a new 6.4 starter with 9 months of life on it. my old 6.0 starter is tired. reason i replaced it it does have a cone that sticks out and 6.4 starter does not... i purchased 6.4 starter on rock auto and have been doing warranty exchanges every time it starts to give me issues. Since i have had my truck i have had transmission out 2 times at a shop 1 for a tranny rebuild and the other time for a cracked flywheel. with in 20,000 miles of trans rebuild. both times a new flywheel was installed. should the 6.4 starter have a cone on it also? my original starter has never given me any issues other than a slow crank.
There are multiple added stresses going on here --- first people think when you add a higher RPM, higher torque, higher AMP draw (especially at initial ramp) starter (6.4L) to the 6.0L it won't put stresses and strains elsewhere like on bolts, electrical pathways, and on that lower weight flex plate in the 6.0L (6.4L's is heavier, "beefier"), but that's simply not the case.
I know there are all sorts of people out there adding 6.4L, 6.7L starters to 6.0Ls --- I wouldn't.
Suspect there is a lot more going on here than a starter issue. With the trans out that many times and broken flex plate I wonder what kind of stress the whole drive train is under. That plate reminds me of my old 460, tow truck would pull like a mule but it could and would eat flex plates.
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