'91 7.3 manual tran. Broken starter.
 

Let me start off by, drove an started fine and dandy since I've had the truck. Even up to last night. This morning I come out to start this truck and turn the key to one crank of the motor then nothing. I repeated to do so about 4 times, the fifth something gave And was loud grinding. So I pull starter and cracked off housing around starter teeth. 2 teeth broke off of flywheel in a row. What caused this!? Also is they're any tricks of the trade to removing the flywheel? I know it's going to be a nightmare getting the big 7.3 out enough to get to it.

I think your starter stuck in the flywheel when you was trying to start it causing the broken teeth on the flywheel.
Can't you pull the trans.from the truck to get to the flywheel, instead of pulling the motor?

I am extremely curious to understand what caused this. And yes!! I wrote this post still covered in grease from pulling starter, I was still so worked up about it I guess I wasn't even thinking straight. Haha (not that I ever do):tttt:. I didn't even remember what I wrote in the post. Just drop driveshaft and bell housing bolts and separate tranny. Still am in shock and aw because of this occurrence. :argh:

Thanks cummins!

Sometimes the solinoid sticks causing the starter to hang up, i'm betting the starter was getting wore out??

Yea, thats how we do it on the big rigs. Pull the driveline, pull the top cover to the shift tower,pull bolts from bell housing and slide tranny back.

You will need to pull t-case and drive shafts .. the Stick comes off at the floor board with the pressing of two little buttons on the shifter @ or right near the base ..

then you will need a cack to pull trans back to get it out of your way .. then you can pull the clutch and flywheel ... there is no easy way to exchange the flywheel anyother way .. can be done in 1 day if you have all the parts on hand .. fly wheels can be had in a day typically .. :tu:

Keep up posted :pca1:

Thank you 4x4! You are the man. I have ordered a stage 3 ceramic clutch kit and solid flywheel conversion. Waiting on parts to arrive, have it all apart ready to put it back together. Has anyone by chance ran or heard of any feedback on the so called Phoenix friction!?! They are the manufacturer of clutch kit/flywheel. Read some feed back online and didn't see anyone saying bad things.

DO please keep us posted on that clutch .. oughtta be interesting .. I will be waiting for your feed back on that .. :pca1: