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Looks like you're on the right track for getting it sorted out. If you decide to replace the radiator, Champion makes a nice aluminum radiator that fits the TD rig. There are some threads here on the site about it. Once you have it sorted out, it's my understanding we should run fleet diesel...

Welcome back TOBASH

The later models were a bit "boxy"....

I have used Carquest Dex/Merc throughout my HMMWV for five years and it's been fine. BDGR

Some folks have opened and repaired PCBs, I'd say it has some salvage value. BDGR

Agree with others to check your glow plugs resistance. It's not hard, and they are relatively easy to reach. Make sure the connections are solid, they can lose their spring and not fasten to the top of the glow plugs well. While it does sound like a glow plug issue, you didn't mention your fuel...

Even at max tuning, a stock OM606 looks to be well below the Horsepower of a 6.5TD, based on WikiPedia details. An OM606 might fit, with enough jamming and adapters, but it might be a very slow ride. BDGR

Better springs on your seat? ;)

Count me in. Question: If we're already a Premier member, does that count? Or is there another way to push the $10 for a second entry? Thanks, Bulldogger

Double polished 40 ga marine vinyl is the standard. BDGR

Until you asked I didn't know there was a Turbo Shroud. My 1987 M998 has a 1990's era 6.5TD stuffed in it using the original cooling stack and we seem to be doing fine. BDGR

I heard they closed (went out of business). Have they reopened? BDGR

I did the same and got an identical response from their Virginia rep when we were fighting the VA HMMWV retired military vehicle law. BDGR

I made half doors a few years ago using frames from doors in that condition. I wasn't able to sell them much, so I'm not particularly interested, sorry, but someone might be for that use or another. Tip: They are reasonable to ship ($$) if you strip them and they can lie good and flat and...

The NP242 (most common HMMWV TC) allows selection of Locked and Unlocked differentials. At highway speeds we run in High (unlocked), off road we put it in High Lock or Low (which is locked). It does produce TC binding to run on clean pavement/flat ground with the TC locked, and the tech manual...

I thought the same thing. Ha!

If someone nearby has access to an old school radiator shop that can boil it out and reseal it, then yes it has value. If not, there isn't much I guess it'd be good for. Maybe some scrap value, but again that's if local services take them in. BDGR

You didn't mention that you bled the injectors. This is always a good idea after making changes to the fuel system. They can trap air and cause symptoms such as you describe. BDGR

I agree under anything but very odd conditions it won't result in a vacuum, it is just to pull air off the hubs and so on to prevent them building pressure and failing seals and perhaps bring a little moisture/vapor out at the same time. BDGR

In case it helps I recently troubleshot a problem with my Wait light. https://www.steelsoldiers.com/threads/removing-unscrewing-badly-corroded-smart-box-plug.203348/#post-2378030 Bulldogger