Have you tried a starter that was meant for a 95+ fullsize, if so I would like to see a pic of what's going on.
I've only tried the ones that fit a '94 fullsize, no other year. I didn't want to start guessing, yet.
Does it feel like the starter "head" doesn't quite fit into the hole? Like does it feel tight or is it scrubbing the opening? I had to grind a lil of the opening to fit mine on my 6.5 before the starter would go far enough in to match the mount holes and flywheel, but it's also a straight mount style starter, not angle mount, but the same thing I'm sure can happen with angle mounts.
The head actually clears, but the main body of the starter hits the dust shield before the bolt holes line up. Beyond that issue, it slides in with no issue.
Forgot to ask, is your's an early or late 94? They made 2 designs for 94.
I honestly don't know. I can provide the VIN if someone knows how to check early vs. late.
Something has always been odd about this truck when it comes to parts. I remember getting the brakes done, and the rear axle seals needed replaced. The repair shop had problems locating the proper seals. I think they ended up getting them off of a 2500 series, or something like that. The starter that I pulled off of the truck originally was slightly smaller than the normal starters from the part store, but larger than the direct-drive starters. I'm very pissed that I took that old one in as a core deposit without at least writing down the part number. Without that, it will be a trial-and-error session for awhile.
I'm going to the part store today to try one more part. I'll take pictures and measurements to see if I can narrow this down, assuming the new part doesn't fit. I've been trying to do this on the cheap, but I'll pay for the direct-drive starter today and pray for better luck.