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If it wasnt installed right it could be the cause. Some of them need shims, more importantly all of them need the brace at the opposite end of the starter. I'd start there.
I cant help with the first 2, but yes, the bolt holes will line up. There is a lot of the mrap 18k lbs winches out there a lot of guys have put on their trucks. Also Simp has put an aussie made 24v winch on his 5 ton and seems to be happy with it. You should be able to find the thread by...
The 6(12, 6 on eaach side) bolts that go through the frame ext into the winch ends are special shouldered bolts. Make sure you find the right ones. White owl had them last time I needed a set.
Doesn't matter plastic or steel, I had my m35a2 steel fan loose a blade. Mine did go through the radiator.
I was flat towing an 818 at the time too. Made for an interesting fix in the wallyworld parking lot. Had to shovel snow to do the swap!
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