Hello, my starter for my 95 f350 w 460 and 5 speed is grinding every start and turning the engine about an inch and the just holds it there until we turn the key to the off position, the engine turns over fine by socket, its grinded the whole time we have had the truck and we put a new engine, starter, clutch and all sorts of other little things, we have the right starter (the manual one) and it's tightly bolted and leveled right but it just has a medium pitched grinding, we also checked the fly wheel and it's got all it's teeth and is fine, same as the starter gears.
(Just to clarify, yes we push the clutch in and even have it in neutral to make sure nothings holding it)

we have no clue what to do at this point because we have spent so much money on the truck, so please if you have and solutions or questions for solutions feel free to either email or comment on this post.

Thank you and God bless
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is the starter solenoid separate from the starter ? if so check the terminal lugs on it for power when the key is in the run position.

 

The starter solenoid is on the starter I believe, and it should be good because the starter is new. And we did also replace the ignition solenoid as a back up, also we took a multi meter to ever wire that has something to do with the starting system and they work as they should

 

Replace the starter again
It sounds like the starter drive is no good

 

we've gone through 3 different starters and they all do the same, we even took them up to auto zone and got them tested and they pasted with flying colors.

 

The starter may need some shim(s). They are hard to find and Ford starters rarely need them, but my guess is it needs shimmed.

 

What does the edge behind the starter drive look like, is it scarred up like its getting smashed into the ring gear ? If not then you don't need shims.
I would put an inductive amp meter on the starter cable and see what it's drawing.

 

The test for a weak bendix spring is not performed on the AutoZone starter test machine
How I learned back at the dealer in the 80's was to see it it will grind wood
You cram a 2x4 into the teeth with the starter on the ground and fire it up
If it chews up the 2x4 the drive is okay
If it just makes a grinding noise and the gear stays put, the drive is no good
You have something mismatched or something bad happening
The drive is where to look
You look at a pic of a Ford SD-302 starter drive and there are differences on the teeth
Ford made 40 some odd drives, You possibly are mismatched somewhere