Why is everybody having problems with the 24V starter??? My starter on my 1986 M1008 was sticking a little too much, so I removed it and put in its place a 24 V starter that I bought from ebay. First thing I noticed was that it was difficult to install. It took me more than an hour to get the front bracket connected and get the starter bolts lined up. Why so difficult? The old one came off so easily. Then when I started, I heard a new sound, a metallic grind/ring. It still started, it just didnt sound good.
When I got my original starter back from rebuild, I put them side be side, then I could see that the Ebay 24V has a bigger nose cone. I took the shield off, and I could see that the starter nose dug right into the side of the engine block. I put my old one on, and it fit perfectly, no contact with the block. Started it up, and no metal grinding sound. It sounded great.
My conclusions:
1) always take the metal shield over off when removing or installing the starter. This way you can see what is going on with the nose cone. With the cover off, you can position the ebay starter a little better, then after the starter is completly bolted in and secure, then put the cover on and tighten it so it fits over the starter, not the other way around (trying to install starter with a tight cover in place)..
2) Best solution is to hang on to your old starter, and just keep getting it rebuilt.
3) I think I was having the sticking problem because the heat shield is missing in my truck, as it is missing in most trucks. I think I was getting a lot of sticking because the exhaust manifold was radiating its heat direction on to the starter, and this probably degraded the lubrication. I wrapped the new rebuilt starter with heat shield tape. I will see how long it takes to get it to stick. So far its been 1.5 weeks and no sticks, no grinds. Starter heaven.
I can see how the block might get cracked. If an ebay starter was installed without taking off the cover, then the nose cone will be contacting the block. All it would take is a slightly loose bolt, then you would get some battering ram action of the nose cone into the block, every time you started it.