The starter in my 1994 f250 460 E4OD just died. Does anyone have recommendations/ experience with "upgrade" starters like Powermaster, DB Electric, etc? Also what is the stock flywheel tooth count and balance for my truck?

 

I don't know the particulars for your engine, but I just put a powermaster starter on my 7.3 and it's never started better. I was shocked how much of a difference it made. I also made new battery cables for it too, full disclosure.

 

I've had experience with PowerMaster starters. Very reliable and would certainly buy another.
Be careful with off the shelf reman starters as they can be hit or miss. I generally search for a local solution with the best warranty. Local parts stores usually have a lifetime warranty on starters, which makes them a great option should swapping it not be very difficult.

 

I can speak to two different FLAPS with some authority, having worked there and dealt with Warranty and Returns.

If you've got the choice between "Rebuilt" or "New" from NAPA/Autozone/O'Reilly/Advance, go with the Rebuilt, at least you're getting a *chance* that it's been rebuilt with quality parts, half the time for things like an alternator or starter, the "rebuild" is basically just cleaning it up, and tossing fresh brushes and some paint at it, maybe bearings (and/or a bendix, in the case of a starter).

Their "New" offerings, I wouldn't touch with a ten foot cattle prod. The quality control is garbage, and while I can't prove it, I'm pretty certain that regardless of which FLAPS you're getting them from, they're all coming off the same assembly line in China, and they're built to the cheapest *possible* price point. That's absolutely where I saw the most number of warranty claims on Starters/Alternators/Distributors/etc.

 

See if you have a local reman joint. Always better deals there and better QC.

The cheaper the unit the worse off you are in my experience.

 

Thats a mighty good point! One that someone without that perspective wouldn't think of. Generally one would think in the case of any rebuild or refurbished, you are getting someone elses junk with some paint slapped on it. In the case of new, one would assume you are getting the best of both worlds, but it seems not! I see your point and will certainly keep that in mind.

I am not sure its an option for you in this case, but in the case of my cummins swap, I needed a new 6.0 powerstroke starter. I obtained a new TYC starter from rockauto, which worked fine for 50 or less starts until my key stuck on. She melted down in short order. To get the truck back on the road, I cobbled the old starter (broken mounting tabs, the reason for the initial replacement) and the nuked starter. Internally, starters are simple creatures and something that one can certainly repair on the bench should you be able to get parts for them. It worked okay but gave me a little crap one day, so I again go on the hunt for a new starter. After reading horror stories of both new and rebuilt FLAPS starters along the lines of what is stated above, I really wanted to get my hands on a FOMOCO starter. Lucky for me, the 6.7 powerstroke starter was almost a direct bolt in, so I sourced a low mileage OEM unit for less than the cost of a FLAPS rebuilt starter and slapped it in. Its been working great ever since. I did the same with my F150; the starter failed and I sourced a used OEM starter on ebay for a fraction of the cost of anything rebuilt/new. Its still working fine nearly 50k miles later.

As i said, I dont know if it will work in your instance, but it might be worth your time to see if there is any starter interchangeability you can take advantage of. Otherwise, depending on where your price point is, I would be looking at a powermaster or the like. Taking a quick peak at Summits website, there appears to be an OE look starter for 160 or so that gets good reviews. I also had a friend install a Summit brand high torque starter in his 460 rig. It works great as well.

 

So, in this case buying a Motorcraft doesn't give you any advantage?? Are they made in C and not Mexico as many of the other Motorcraft parts are labeled?

 

I said FLAPS. Can I guarantee that a New Motorcraft part is going to be perfect? No.

FLAPS parts sourcing is primarily based around price point first, and quality second. (not in all cases, and for all companies, but I've been around Aftermarket Parts in Automotive and Heavy Equipment for close to 30 years, so I think I've got a pretty good perspective on this)

But Motorcraft (and by extension Ford) puts alot of value in being known for selling quality replacement parts, so their QC policies and procedures are considerably more stringent in my experience. They are generally far less concerned as being seen as the "cheapest".

Please refer to Idle Air Control valves, Throttle Position Sensors, and Ignition Coils, if you doubt my assertion. The aftermarket offerings for OBS trucks that use the EEC-IV engine management systems are a crapshoot, at best.

 

I am leaning towards the powermaster 9505.

 

Its a good option! I had its Chevy LS equivalent in my LS-swapped Jeep TJ. It worked awesome. Had a small issue with the starter and PowerMaster took care of me free of charge. Their customer service is fantastic!

 

OP,

We'll 2nd the Powermaster PWM-9505. It will have plenty of torque to spin over your 460. Its small size and "infi-CLOCK" 360* rotation clocking adjustability make it great for fitting in tight places. If you have headers or plan to run headers those will be great benefits.

Regarding your stock flexplate. That would be a 164 tooth external balance flexplate like the ones listed here on our site.