I have a 2000 F150 with 5.4L Triton. I purchased it used approx. 6yrs ago. Ever since I have had it there has been issues with it starting. Periodically when starting it...it sounds like the starter is not making good contact with the flex plate and it makes a grinding noise. I have replaced the starter 3 times and the problem still exists. Even tried 2 starters in 1 one week. A friend checked the flex plate and there are no teeth missing and appears that it is not warped. Could this be one of the motors that needs the starter shim that ford used to make? Anyone have any ideas?

 

i have a 97 f150 with a 4.6 and i also have the same problem about once a week when starting it i get a grinding noise and sometimes it happens more than once at the same time when starting the truck. but i haven't put in a new starter for awhile..

 

Are you using New or Reman starters? For some reason I havent had any luck with "New" aftermarket starters. Getting a Reman that has a factory casing typically solves my noise issues. Just my experience.

 

Aftermarket starter castings have less stringent quality control.

Sometimes you need to ream the bolt holes on the side away from the gear connection so you can slide it closer which allows the gears to mesh the way they should.
{you will need three hands to hold the starter in place and bolt it.}

 

I would also guess for some reason the starter is not lined up properly. Did you replace all bolts,washers, etc. with new ones? And are you sure the bolts are pulling all the way up as they should? Maybe someone replaced a bolt with one that is a little too long, or short, or not the proper diameter and it is not tightening down as needed and causing alignment problems. If you think that might be the case, you should go to the Ford dealer and buy the factory bolts, they are not that much.
Use a torque wrench too.

 

I used the bolts that came out of the old starter. It appears to draw down tight to the motor. I read there were issues with starters on trucks a couple years older than mine. That's why I thought it might be a shim problem.

 

Have they same issue with mine and I've changed starters too. When that didn't work I had ford look at the flywheel and they said it was fine but I've heard from several others that it is supposed to be some nicks in the flywheel where they can't be seen easily. I've lived with it for years now and might eventually get it all changes out.

 

lol my 2000 4.6 does the same thing lol i am not alone