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In the process of rewiring the controller I had to reuse some of the terminal pins in the connectors on the switches. I thought I would show how to do that. Some pins are harder to do this with but there are times when you have to reuse what you have. The 5 wires circled in red needed to be...

I worked on the winch control and wiring today. In a previous post I mentioned I wanted to use a Heavy Duty Winch Controller from a larger truck that most likely had a variable speed winch. The variable speed part would not apply to my winch as they just don't support it. I did find a...

I've made lines before and I think with the extra lines I have now I should have enough fittings to do what I need to. When I get to the rear steering that might change. Thanks I do not make a living at this, just a hobby. That said, I have a few tools and toys and lots of experience with...

What's the difference between a pregnant woman and a Humvee hydraulic fitting? You can unscrew a Humvee hydraulic fitting. I thought they were crimped on fittings but luckily they are not. The 120 degree fitting goes to the brake booster. I had a spare hose so I removed the fittings. I'm...

Finished mounting the winch to the control arm bolts and drilled the holes and mounted to the bumper brackets. Then I had to fit the hydraulic lines to the winch motor. I had to tweak one of them to clear one of the solenoids. You can see in the picture below how the line bends slightly...

Yes but only across 1 battery. If the other battery is dead that it might not work. If you have 1 battery that is weak then you can use that battery pack on the weak battery. You CAN NOT put it across both batteries. If you have 2 battery packs then you could put 1 on each battery.

Now that the bolt is out I lined up the winch to check for clearance. One of the solenoids hit the frame before it was all the way up in place. I removed the nut and rotated the solenoid and it fit perfectly. Rear winch fits like a glove. With the winch bracket in place it allows me to...

The bolt is OUT !! Ultimately putting the a spacer (washers) and nut on the bolt threads and using an impact was able to pull the bolt through. The impact worked the entire time to pull that bolt through, it was not easy. I had to increase the spacers twice to complete the task.

The way I read it, it was one sitting on the self and yet to be used in the truck.

I don't think there is a strength issue with a well made Aluminum radiator and that begs the question if the Champion radiator is well made? I have no idea. Is the OEM HMMWV radiator well made? You can bet money on it. Here is a good article I found comparing Aluminum vs. Copper/Brass...

The original OEM radiator is pretty tough in general. I had mine "fixed" at a local radiator shop, you can read about it starting here https://www.steelsoldiers.com/threads/my-new-1992-m998-avenger.184818/post-2359161 Then I fixed it myself. I would do a good flush of your radiator and get it...

The cost is only a part of the problem, even the least expensive ones weight a LOT and packaging doesn't protect them well. I've been looking for one in the $2-300 range withing 200 miles but I haven't found one yet. And each machine only does 1 size.

I have no idea what they used for the HMMWV or anything else but when I went looking I found Stencil Machines on epay. If you do a search for Military Stencil Machine you will get lots of results. Two common models are Marsh and Ideal. They are die cutters that write what you want in a cut...

Thanks for the suggestion. A left hand bit is usually used when a threaded bolt is seized in a threaded hole. The left hand bit can help release the clamp load of the threads and spin it in the right direction to unscrew it. In this case it doesn't matter, the bolt isn't threaded in, it's...

Thanks for the feedback and advice. As of right now the bushing is no more "toast" than the rest of them. That said, the bushings as well as the rest of the truck turns 30 years old this year. ALL of the swing arm bushings *could* be replaced but none of them are so bad they *need* to be...

Thanks but I am not a beginner at difficult to remove bolts. I would like to touch on a couple things you suggested though. First, there is NO way you are breaking these bolts with an impact. The shank is 5/8" thick and it is rusted in place in a rubber bushing. You would rip it free from...

Thanks for the recommendations. A block of steel that big and heavy would be very difficult to hold in place if I had one. I did check everything after each attempt with the jack hammer to make sure I wasn't doing unnecessary damage.

A 30" 1/2" drive extension is pretty handy too. IIRC I had 1 person up top through the doghouse and 1 under with the extension. Might have had a swivel also.

The Fun begins! The first step is to turn around the rear control arm bolts. This is the same process used when mounting the front winch. You can see I have 2 - 6" x 5/8" bolts (circled in red). After removing the nut from the control arm bolt I use one of the 6" bolts to drive it out while...

I did my y pipe with the starter in place no problem.