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Yes, going to a 208, the TH400 to NP208 adapter wont work because the adapter centering ring is to big to plug into the transmission housing, 4L80E, so, I bought a 4L80E to NP241 adapter off epay. The unit on the left is the stock 400 to 208 adapter, and the one on the right is the 4L80 to 241...
Spray on engine degreaser power washer with hot water and then compressed air. The case was very clean to begin with. I thought about taking it and having it cleaned, but it came out just fine with a driveway power wash.
Wait, I just realized what you where asking, there are actually 2...
Ok, so I'm going back together this weekend with the new parts, and the 4WD short shaft. Remove the snap ring on the output gear assembly and swap in the short 4WD output shaft. I'll try to get a P/N for the correct 4WD shaft.
The part number for the 97-07 fitting is 24233367, the part number for the 08 and later is 24236581
http://www.tonkinonlineparts.com/p/__/FITTING-Transmission-Oil-Cooler/6598477/24236581.html
Ok, some more info on the teardown. The rear oil cooler fitting on the transmission MUST be removed prior to removing the rear gear assembly, ask me how I know. . . . The ATSG manual, and the HMMWV manual do not indicate it needs to be removed prior to removing the the rear gear set.
My GL...
Ok, I just solved this problem on my 1028A3, the truck was very hard to start, smoked a ton before it started. The problem is a leak at the fuel filter housing, between the filter and the housing, I installed o-rings on the hard lines on the housing to make a good seal between the fuel filter...
So I got my A3 lifted and new tires installed. 4 Inch front 3.5 back, then 255 85R16 BFG KM2's I absolutely love the way this truck looks now!!!! Thanks to Kenny for the info on the tires, apparently BFG does not make these anymore, so I'm ordering another set of 6, walmart has them for 226.00...
A diesel is not like a gasoline engine, you cannot run a diesel "lean", your boost/temps sound fine. sustained 1000-1200 degree egt's are what you need to stay away from.
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