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Being as it is getting air in the system while running, that tells me the leak is on the suction side. That's why I said it has to be between the fuel pickup and the booster pump.
If you plug the return, don't leave it running for 20 minutes. I don't think it would like that. I would do short 5 minute spurts, since you are dead heading such a small electric pump.
Or keep an eye on it to see when it starts to get hot. It may do ok for quite a while that way.
And...
There is a small chance, like I said, but it is really just a light connected to a switch on the park brake lever. They were added to many single circuit trucks as well. I just finished rebuilding the dash harness in one last night, save for the blinker switch pigtail.
You need to use grey " gear oil" silicone. Permatex makes it and it says "gear oil" on the blister pack. Other silicones just don't hold up to gear oil very well.
Probably the soft line on the lift pump inside the tank. I've only seen one or two that WEREN'T rotten.
Whatever it is, it is going to be between the lift pump and the booster pump on the injector pump.
You can plug the fuel return line where it comes off the secondary fuel filters and turn...
That isn't a bad idea at all. Some grease in the proper place would help too, but tearing each wheel end down just to apply a little bit of grease is off putting at best.
A wrecker chain, couple of huge hardened padlocks, and a large tree would work for that. Chain the rear axle to the tree. They would have to bring a torch.
Edit: OR a chainsaw...
Forget it. If his truck has been there for more than a couple of days, there won't be anything left worth bringing home. If you try to cross the border in a military truck with camo paint, you will be arrested and thrown in jail.
I'm just going to say this, because I want no part of a technical pissing contest here...
The 2.5 ton truck (m35a2) is rated for 2.5 tons, payload, or towing offroad. On road it is rated at double that exactly,until you get to the C model trucks, which they down rated for some reason...
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