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The starter cable on my 1009 was routed from the 24v bus bar under the frame and to the starter when I got it. This seems unusual and I'd like to return it to the factory routing, but haven't found a diagram in the TM showing what that would be. Can anyone share a description or photo of how...

Yes. There is a $150 core charge which is not refunded if you do not send the old pump in, but if you pay it you do not need to send in the old one.

I bought it from Badger Diesel on the recommendation of a few members here. He was easy to deal with on the phone (a bit gruff, sort of reminded me of myself haha), and was up front about having a large backlog of parts ahead of me in his queue. I got the pump delivered about 3 weeks ago after...

I installed the new pump advanced by the width of the reference line. It was significantly advanced before and ran well, so hopefully this is a good compromise with the new pump. I'm sure I'll have to adjust it, but I'm just looking for a good baseline to get up and running. Photos of the new...

Sounds good, thanks. I was thinking a stretched chain would retard the cam and IP timing, so maybe someone was trying to bump the IP back to where it should be relative to the crank. Of course the valve timing would still be off in this scenario, but a timing set is more work than bumping the...

I'm replacing the injection pump on my m1009 and after cleaning off all the grease I noticed the timing mark was significantly advanced, about 0.100" Why would the previous owner have advanced the pump like this? To compensate for a worn timing chain? The truck ran fine but the IP was leaking...

I got the 6.5 heat shield, will try to fit that up this weekend. I think that will help a lot. The latest issue is apparently the SM465 slave cylinder interferes with the driver side exhaust manifold. Has anyone ever had a manual in one of these trucks with a 6.5 turbo? If so what did you do...

Ok, a short update with a couple more questions and photos With the short injectors installed and a tiny bit of bending on the starter heatshield, the turbo manifold seems to install without any interference. I don't have the injector hard lines on yet but I think they will clear no problem...

Plus the M1009 already has huge 24v cables going to the distribution panel by the bench seat, so it would only require adding a single 12v wire. This is what I'm planning if I can't fit them under the hood, but was just wondering if anyone has done it already

The driver side is kind of a disaster, with an ac compressor and 2 air compressors. Not much space over there. The batteries need to be on the passenger side, or back under the bed floor/in the cab probably

Thanks. I'll take a look at group 65 batteries if I can't get my 31s to fit. They're less than 60% of the weight which should definitely help with the fender breaking. They have about half the capacity of the group 31 though, so I'll probably need to add another battery for my refrigerator...

So, I got the 6.2 manifolds off over the weekend. It took an average of 30 min per manifold bolt, but I didn't break any of them in the block. So that was nice. I ended up pulling glow plugs, injectors, and moving all the engine wiring out of the way and made space to use the acetylene torch. It...

Thinking about this a little more, is there any advantage to replacing a head gasket which is not leaking? I don't want to use studs, so I would be reinstalling with a new set of factory style torque to yield bolts. I'm worried if I take the heads off and the head and/or block surface is not...

Do you need to take the hood off to lift the heads out? They look pretty heavy (60-80 lbs?) and I'm not sure how to set them back on without disturbing the hee head gaskwt

Does anyone have advice for removing stuck exhaust manifold bolts? I've been spraying them with PB Blaster every day for a couple weeks, but when I tried to remove them this weekend they were still stuck pretty tight. I usually just go straight to an oxy acetylene torch and get everything nice...

Does anyone have a good source for sheet metal for these trucks? My front inner fenders are a bit rusty, and the passenger side is cracked where the battery tray mounts. I definitely want to replace the passenger side, and am trying to decide if there's any difference in fit or quality between...

Yeah I agree, its too low for this setup. I am in K5 on 33" tires, 3.73 axle gears, and a SM465 manual trans with Advanced Adapters "Ranger" overdrive. Cruise RPM is 1900 at 70 mph. I'm hoping for 18+ mpg with that setup, but we'll see what I can get. No smoke visible in the daytime, and just...

I got a bunch of 6.5 parts several years ago, and am finally getting around to installing them on my 1009. I have some questions about assessing engine condition and I am sure I will have more questions as I work through the swap, and will document everything here in the hopes it helps someone...

My 1009 has been a daily driver for 5+ years, and the engine runs fine. Never had any shavings in the oil at oil changes, no knocking while running, or any other evidence of extreme wear. The "Low Oil Pressure" warning light comes on with the key, and goes out immediately after starting the...

I am getting ready to do a 6.5 turbo swap into my M1009 and am starting to collect parts, and have several questions. I've seen Diesel Care in Memphis recommended by Cucvsrus and others on here, and their IP rebuilds seem to run between $450 and $750 depending on what you buy. They don't...