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How long do they normally last before they swell? The last thing that I want to do is go through another broken glow plug repair job. There's nothing quit like laying on top of an engine compartment for hours on end. I felt like I was beaten and whipped after that job was finished.

Did you need a special wrench to remove the IP mounting bolts? I've seen at least two different wrenches for those bolts. One was S shaped, the second one was slightly different. I've also seen a tool with pins that is used to rotate the injection pump. I'm aware of the static timing tool, but...

Thanks for the info. My mechanic buddy told me that they don't sell the windings. Perhaps they don't sell the ones he needed for the limos that he used to work on? Do you know off hand who sells the replacement windings? I've got a full rebuild kit from CUCV Electric but they don't sell the...

When I first got my M1009 over the summer everything seemed ok. Then my rear battery took a crap on me this fall so I replaced it. In a few weeks the rear battery died again. This time I replaced the front battery and I got the rear battery replaced under the warranty. Less than two weeks later...

Just before Christmas my M1009 would no longer start in cold weather so I ordered a set of glow plugs. Then to my surprise 6 out of 8 glow plug tips broke off when I took them out. The only good thing about this is that the tips didn't just swell requiring a glow plug removal tool, instead they...

I just put a set of Diesel RX glow plugs in my M1009. You can buy them for about $60 bucks a set on Ebay from various diesel repair shops. The Diesel RX plugs are made specifically for the M1009 and the M1008 CUCVs. The civy model plugs have a wider blade and your stock military slip on...

Thanks for posting that file, it's going to help. We need to share notes on this project. Regarding the sending units I suspect that the sending units might be the same for both the gauges and the indicator lights. This isn't confirmed but I can't seem to find any sending unit that was made just...

I think I have a simple solution figured out. The civy gauge cluster has an empty spot in the bottom left area where the gen 1 light is on the M1009 gauge cluster. There's nothing in it and there's a blank spot on the backing plate to create a hole for a bulb socket which won't interfere with...

Thank you for your help. Things weren't as bad as I had initially assumed. When I took the gauge cluster out I found that it didn't have any broken circuits. The problem was corrosion on the bulb socket contact points. I used a tiny piece of a Scotch Brite pad to clean off the copper contact...

From what I can figure out so far the civy gauge cluster has one indicator light where the gen 1 is supposed to be. It might be possible to switch a wire or two in the harness so that you can use the indicator light circuit in the civy version as the gen 2 light, provided that you have already...

Thanks a bunch for that website.

I took my dash apart today to replace several burned out bulbs behind the gauge cluster and that's when the problems started. After a little tinkering I realized that it wasn't the bulbs at all. It turned out to be a damaged printed circuit board. Who ever the military mechanic was who worked on...

Do you know if the starter relay was a problem in civilian trucks? I read one of my manuals that Chevy corrected the starter relay problem in the 1986 CUCVs. Then again the popular piece of advice around here is to replace it anyway.

Nice build and the new motor looks great. And thank you for the link. I downloaded several pictures of the Banks system for reference purposes. As long as I can find an aftermarket AC system with a drivers side mounted compressor I'll be fine. I need to make some calls and see what's available.

The 12 volt conversion requires that you keep the passenger side alternator, so that's good news. What brand of aftermarket AC kit did you install, or was it a pieced together factory version?

Yes, I have a copy of that file and I'm going with the version where you eliminate one alternator and keep both of the batteries. I want to increase the reliability of my truck which has already started giving me problems with the charging system. Plus I want to add 12V accessories to the rear...

Has anyone done a Banks Turbo charger conversion along with an aftermarket AC kit installation? My plan is to convert the truck over to a 12 volt system with a single alternator, and install both the Banks Turbo and one of those aftermarket AC kits. I need to know what alternator I should...