Sounds like an issue I've had before (not with the PSD) where the starter internals were not lubricated and if I remember correctly, the bendix wouldn't allow the starter gear to align properly with the flywheel. It would strike the flywheel by the teeth and cause a nasty clunk.

 

So your pretty sure it's the starter? I don't mean to doubt I just want to be really sure, I just dropped $400 on batteries I didn't need and the fiance' was pretty cool about it I don't want to push it too far though lol

 

Just merely a suggestion. Without seeing it in person its hard to diagnose. Make sure you check all wiring from batts to starter and grounds. Check for anything that may inhibit conductivity. BUT from what youre stating and my past experience (although Im not a mechanic by any means), it sounds like the bendix is the problem. If all wiring looks good, good connections, grounds, etc then Id take the starter off and check it out. Look for any wear on the gear and flywheel (like I said it seems as though the gear is not properly meshed with the flywheel and youre hearing the gear hit flywheel teeth).

 

I THINK THAT WHAT AgTires4295 SAID IS PROBABLY YOUR PROBLEM.....

YOU CAN TAKE THE STARTER OFF AND HAVE IT TESTED AT MOST CHAIN AUTO PARTS STORES FOR "FREE".....AND LOOKING AT THE FLYWHEEL FOR CONTACT DAMAGE / SCRATCHES WOULD GIVE YOU MORE INFORMATION ABOUT THE POSSIBLE STARTER FLYWHEEL CONTACT ISSUE.....

ONE OTHER THING TO DOUBLE CHECK IS THE CONNECTIONS ON THE STARTER.....THE WIRES CAN SOMETIMES SEEM TO BE TIGHT ON THE SOLENOID.....BUT THE SOLENOID CAN HAVE A CRACK ON THE INSIDE THAT IS MAKING THE ELECTRICAL CONNECTION LOOSE POWER DURING STARTING.....AND THUS CAUSING THE CLUNKING NOISE AND STARTING ISSUES YOU DESCRIBE.....

 

Sounds like starter hitting flywheel also. Have someone do it while you lay under it. See if you can see where is is coming from. Maybe put your hand on starter and you can feel the shock of it.

 

I just found this and realized I forgot to update. The Ford Dealer in Woodstock, GA (I won't mention any names....) had forgotten to tighten the power lug on my almost brand new starter after they put my new TC in. As a result it was arcing all over the place and melted the threads of the post. I replaced it with a gear reduction starter (that thing was awesome) but it died after a pinhole got rubbed into a fuel line in the valley and the fuel dripped down into the starter. I replaced it with one from a parts chain because I was working out of town and it's been there for about a year with no issues.

 

Better late than never. LMAO.

4 years since the last post in this thread MR. CAPS! He has his truck fixed, and just updated the thread 4 years later.

And dude, LOOSE THE DAMN CAPS! The internet has been around for about 20 years. All-caps has been considered "yelling", rude, and inconsiderate since the very beginning. Knock it off.