How to Replace The Starter On A 6.4L Powerstroke 2008-2010

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Today we will be showing you how to replace the starter on a 6.4L powerstroke ford truck this is going to be the same for the 2008 thru 2010 ford trucks. So to start we are going to open the hood so we can access the batteries. With the hood up we can grab an 8mm socket and ratch and remove the negative battery terminal connection. This is a dual battery truck so we will be removing both negative battery terminals. You may want to place a rag over the top of the terminal just to ensure that the cable doesn’t come in contact with the battery terminal.

With the batteries disconnected we can now climb under the truck on the passenger side right behind the passenger front tire. Once underneath we’ll locate the starter. It will be just below the passenger side exhaust manifold and up pipe. To start the removal of the starter we are going to grab a 13mm socket and a swivel headed ratch and remove the nut that holds the bracket in place for our wiring for the starter. 

Next we can put a 10mm socket on the ratchet and remove the nut that connects the signal wire onto the starter. Next we can put on a 15mm and remove the nut that holds the main power wire to the starter. With all the electrical connections removed we can slide the bracket off the stud and tuck the wires out of the way. 

For the next step we are going to need a stubby 13mm wrench to remove the top bolt that holds the starter in position. If you have a ratcheting stubby wrench that would be even better to remove this bolt as there is not a lot of room to get good turns of the wrench. Once the bolt is loose we can completely remove it by hand.

With the top bolt out we can move onto removing the middle stud so we will need a 13mm deep socket to remove it. Well get it loose and remove it completely by hand. Once we have that stud removed we can remove the last bolt at the bottom of the starter.

With all the bolts removed we can now remove the old starter from the truck. To do this we will wiggle it free and slide it out down and towards the downpipe. With the starter removed we can grab a rag and clean the area where the old starter was ensuring that the matching surface between the starter and truck are clean.

Now we are ready to reinstall the new starter but before we do i’m going to remove the washers and nuts off the electrical connections as I think we will have less of a chance of dropping them if we were to remove them after the starter is installed back into the truck. So we will grab the new start and wiggle and get it into position. For this truck we decided to use an XPD diesel gear reduction starter

Once we have the new starter up and in position we can align the holes and start the bottom bolt. We have also decided to buy the XDP black phosphate black bolt kit. So we’ll grab our new bottom bolt and start that by hand and just snug it up as we want to be able to wiggle the starter around to start the other bolts.

With the bottom bolt starter and somewhat tight we can now grab the factory stud and insert that into the middle mounting hole. We decided to use the factory stud instead of the new black bolts just to be able to reattach our bracket for the wiring for the starter. Then lastly we can going ahead and install the last bolt into the top bolt hole.

With all our bolts started by hand we can now grab that stubby 13mm wrench and tight the top bolt. Once we have that one tight we can tighten the bottom bolt which is now going to be a 19mm because of our new replacement bolts. Once we have the lower one tight we can grab a 13mm deep socket and tighten the middle stud down. 

Now that we have the bolts tight holding the new starter in position we can now grab a piece of sandpaper and clean the terminal ends that attach to the starter. Once we have both ends cleaned up and can slide the bracket back onto the stud and out power and signal wire terminals back onto there lugs.

With the wires in place we can grab the lock washer and nut for the power wire and start that by hand and get it hand tight. Once we have that one on we can grab the nut for the stud to hold the bracket in place and start that one by hand and get it hand tight. Next we can grab the lock washer and the 10mm nut and install that to hold the signal wire onto the start lug. 

Next we can grab a 16mm socket as that’s what size the nut is for the power cable on this new starter. Well get that nut tightened down. Next we can grab a 10mm socket and tighten the nut for the single wire. Next we can grab that deep 13mm and tighten the nut onto the stud to hold the bracket in position. That completes the starter install.

With the starter in we can now reconnect the battery terminals. This is a good time to clean and protect the battery terminals from corrosion. They have this convent kit to do this. So we’ll place the negative terminal end onto the negative terminal post of the battery. Once in position we can grab an 8mm and tighten it down. Be sure not to over tighten it and should just be tight enough to not be able to wiggle it. With both batteries reconnected we can start the truck. 

As you can see the truck started right up in 20 degree weather with ease. We will run the truck around tomorrow just to ensure multiple starts with no problems. So the problem that this truck had was it would start fine the first time with the engine cold and then you would shut it off and it wouldn’t start back up. If you let the truck cool off for a while or turned the key a bunch of times you could eventually get it to start. Which led us to believe that there was a bad spot or two within the starter. 

So that’s it we have just shown you how to replace the starter on a 6.4L Powerstroke Ford F250-F550 and years 2008-2010

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