Sorry guys I tried to delete the posting but it wasn't cooperating so I just edited everything out. Anyhow, I've had my M1028 apart for about 4 months waiting for some time to replace the Flywheel. I replaced the flywheel(I know I know, its a flexplate) and it started fine but after about 10 seconds it started making a clicking noise. It would make the sound in all gear ranges except reverse. If I shut the truck off it would be quiet on restart then after 10 seconds it would return. I did not drive the truck. The first thing I thought was the bolt on the flywheel but they were tight. I checked everything and everything looked right. Late last night I went back out and took a look at everything real close with my headlamp and I noticed the weight on the engine side of the flywheel was touching the starter housing(endcap.) I didn't see it before because every time I looked at it the weight wasn't in that position and it wasn't making any obvious damage that I could see. So either the weight or the end cap were over sized. Just by a 1/16th of an inch or less. I wasn't going to mess with the balancing weight so I trimmed down the end cap on the starter, just enough for clearance. (The head of my starter was cracked and I had a new end cap put on it last year but I didn't want to install it until after I replaced the Flywheel.) I marked the area I cut down with a sharpie just to make sure it wasn't rubbing even it I wasn't hearing any noise. Everything looks good to go.
Thanks guys and sorry I left you hanging like that.
Robert Setzer
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