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Advice to the wise: stick with the 3 lever switch. While the E version looks cool they're no more reliable and to operate it you need to look at it whereas the 3 lever switch can be operated by touch.

Be careful when you measure the batteries and charging circuit. A new set of batteries will hold the voltage down to around normal when the alternator is not regulating properly. I had an M151 once that cooked the batteries and when I measured the alternator it was reading 28.9 volts in the...

These trucks will run on the IP alone even with a bad fuel pump until they get stressed with low tank levels and then they'll die like yours did. The fuel pump isn't hard to replace and readily available but there are a few tricks to making the job easier. There's no need to buy a "HMMWV fuel...

And after you've done all this go to the G503 site and read Steve's excellent post about starting issues here: https://forums.g503.com/viewtopic.php?f=63&t=230913

There are several sensors and switches on the HMMWV engine each with a different purpose. The sensor behind the alternator near the front of the left cylinder head is the signal to the temp gauge. The temp switch on the intake manifold is the signal to the cooling system. The temp sensor on the...

Did you check the cold start switch to make sure it's working? It's there to help the truck start in cold weather. As for a mechannic, check with Dave Hamilton over in Tooele at Hamilton Diesel Service.

For the soft doors the strikes are simple wire brackets. I made mine out of 1/8" aluminum rod with a Harbor Freight bending jig. The right and left door handles are different, front and back are the same on the same side.

Your LED lights don't draw that much power so what I did was to tap into the circuit that lights the shifter lamps. That way if I don't want the backup lights to come on I just leave the dash lights off. The other advantage is that wire is already in the shifter.

Looks like a marketable product to me!

Thanks Greg. I thought I already had this app note but this one is different from mine and is definitely a step up as it shows all the 150 configurations and cable numbers. Now I just have to find some of them!

When I mounted the new neutral start switch into my shifter to use for the backup lights I took the switch to the local hardware store and matched it up with the switch threads and the shifter threads. The part was an off the shelf brass reducer with standard pipe threads. I did cut it down a...

One of the simplest things to use to test this is a clamp-on current meter. Be aware that the majority of them used by electricians are for AC only and you'll need one that measures DC. They sell anywhere from $25 on up. It's a good addition to any toolbox because they're also general use...

This may sound like something obvious but are you sure you have the correct bailout cable for your Comtac headset? When I was working with my Racal 5000s trying to get the audio to work I came across some that looked the same but were wired differently.

The factory manuals are almost as unobtainable as the cables but luckily there are some online. It's pretty hit-or-miss as to whether or not they have cable pinouts in them. The other thing about Harris is their (intentionally?) confusing system of nomenclature. There are multiple numbers for...

Does anybody on the forum have access to cables for the Harris radios like the PRC-138s?

Unless you have the upgraded Wildwood calipers the originals are '87 Eagle calipers and cost about $18 at most auto parts stores, no cores necessary. Just replace them, it's less trouble than trying top rebuild them.

The M37 starter switches can carbonize up after years of use and cause current draw. Disconnect the battery lead from the switch and see if it goes away.

There are also other forums that will have them like the G503 and G838 websites.

When you compare the investment in the commanders seats and their benefit to all of the other cubic dollar investments people put into these things yes, they are a good investment. The ride comfort is a world of difference better. It's comparable to going from bias ply tires to radials.

The MX777 is a transient suppressor and not a noise filter. Internally it's just a big diode. Do an online search for 24V automotive noise suppressors. They're readily available and not very expensive, in the $10 - 20 range.