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In case you cannot find the instructions

This tachometer has 3 DIP switches on the back , set #2 on, the rest off. Use the fine adjust for 625 RPM @ idle. Instructions are online.

The Helicoil should work if you can get the tap deep enough. Helicoil taps work like any other tap, the ones normally available are starting taps, fine foe through holes. This fitting is a blind hole so you may need a bottoming tap. These have only 2 of the first threads tapered instead of 6...

Sand bag improvised armor in the M1008A1s?

DOT4 and DOT5 are not compatible, you will have problems soon as these gel when mixed.

Old master cylinder had DOT4?

Copper on aluminum will cause corrosion in the aluminum when it gets wet. Or even humid.

Odd that the battery voltage is higher than the alternator. Sounds like front battery ground or passenger alternator negative connection problem.

I've repaired a few of them. Far better than the MTD models in design. AYP are a bit better than MTD.

Starter bolts break because of fatigue. This is evident in the very low deformation of the fracture plane, the pieces fit together tightly. A bolt failure from transverse shear would show offset deformation. Tensile failure is indicated by necking or reduction of diameter at fracture plane...

Yes, automotive standard 12 volt coil. Detailed on wiring diagrams.

One is the excited circuit for passenger alternator, the other is the voltmeter. Both needed to remotely switch these circuits from the 12 volt ignition switch.

Great info ssdvc! With a new radiator, new rubber mounts are a good idea. Prothane makes urethane copies. This minimizes electrolysis which is the prime cause of aluminum failure.

I have the VDO tach mentioned in the quoted thread. ISSPro uses a Hall Effect or magnetic sensor, requiring 2 magnets to be installed on the crank pulley. Far from ideal because that is 2 pulses per revolution. And gluing magnets to the crank pulley is another failure point. Alternator...

The M1009 uses different high pressure accumulator, pedal rod and that bracket. The one ton brake system has larger wheel cylinders and needs more force as the master cylinder is correspondingly larger. Use of a M1009 on a one ton will reduce braking power. In proper functional state, CUCV...

Looks like an o ring type fitting. Should be a standard part but I don't know the size. Surplus Center has good tech info on fittings. https://www.surpluscenter.com In the technical section. If you have a thread checker, 90% of the guess work is done.

I have that tachometer in my CUCV, running off the driver side alternator. No adapter required. The tach terminal is variable frequency alternating current from one of the three field windings. Most traditional tachometer use the ignition coil primary voltage which is a variable frequency...

The parts technical manual 9-2320-289-34P has the GM part numbers. 1 ton use 2770209. M1009 use 2770317. The acronym UOC in the parts TM is Useable On Code, each CUCV model has its own UOC. The M1009 is UOC 209. This is all detailed in the preface of the TM, Section 1 page 4. M1008 is 208...

Older GM NV4500? 6.34:1 first is a nice touch.

Too long only matters if the shock is fully compressed before they bump stop is reached. Using a shock for rebound travel limit is common.