My '03 F350 ZF6 is getting a 12V transplant in the next couple of weeks too. As soon as my engine builder gets done. I'm not going to run the adaptor everyone tells me I should, I've opted for the Ford/Cummins Conv. and I have many reasons. Biggest thing I was worried about was pulling the front end off the truck to lift 6.0 and replace 5.9. So much of the engine is under the cowl it looks like a bear to get to. I have opted to not use the post lift to remove cab, but gonna use a trackhoe to lift with since it has such precision movement and with the whole front end taken off, it should not be too bad. I can't imagine what's going on with your starter other than the fact that the rebuilt ones are junk. If you are not buying new at Ford or IH, it's probably junk reman with aluminum windings instead of copper like new. Just a thought. Steven.