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Replaced my starter on my 7.3 Excursion this past weekend. New one was a great deal larger but reviews and all I read says it'll work. I now how a "grinding" noise... Any idea on the cause. Thinking based on sound teeth aren't catching flywheel.
 

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yikes! What was wrong with the old starter?
Which starter did you install?

If the pinion gear is not kicking out far enough it may be a voltage issue, meaning the cables that feed power to the starter may have corrosion? I would check voltage at the starter make sure it is getting full battery power. Make sure battery power is 12.2V+ at least......
After that I would bench test starter
If you bought a re manufactured starter You can suspect it bad right out of the box, it happens
 

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FWIW all a bench test that most parts store preform only shows that a starter will spin over and that Bendix engages. Load test is the only way to really test if a diesel is any good or not, which most of the time only a starter repair shop can perform. I have taken them in in the past and parts store said it pass the bench test and the starter was bad.
 
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