I have a 94 6.5 Turbo. When I turn the engine over, it will nearly start then the bendix pops in then out again. It does this a couple times then starts right up. It mostly does this when the engine is a little warm. It usually starts right up early in the morning without problems, the colder it is outside the easier it is to start. What the heck could this be?
I changed my starter a couple months ago because of this and it still does it!

Have you checked the clearance with the flywheel? Sounds like your alignment is out, might need to add a shim or 2.

I've read the starter on the 6.5L can develop problems if you don't have the correct bracket in place.

Oh yeah, thats a big problem too, if you don't have the rear bracket on, or if its loose/broken, then you could cause major problems, like shearing the bolts or pulling the threads right out of the block, trust me, this is not a place where you want to try and helicoil.

This started happening after the flywheel got changed. The mechanic told me that he had to put 2 washers on 1 side to make the starter line up. It seemed to be doing fine for about 1 month. I took it to another mechanic and he said it might be the timing so he turned it a few mm, and it got worse.

could the starter solenoid do this also?