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No. Not a design flaw. "Lowest Bidder" is the answer to your question. I installed a BRAND NEW one out of the package and it was still exactly like this. There are no slots on the box or the latch and the rivets fit the holes tightly. That's just the way they made them.

You probably don't have it if you don't have the fuel lines to connect to the van. Mine was also missing. I used a 24v Facet military pump to lift fuel up into the heater tank and then the diesel heater has it's own dosing pump that is gravity fed from the heater fuel tank.

Yeah I was thinking that also but it's not easy to remove. You could likely bend it without removing it.

I replaced one of mine that was bent and the lock was broken. They are riveted and the holes are not slotted. Finding a replacement was exceptionally difficult. If I were to do it over I think I would maybe try to adapt the latches used on the PDP - which I found can be purchased reasonably. Or...

Maybe some weatherstripping to push the lid up higher? They are all like that BTW. Shitty design.

What kind of heater are you using? The stock pump may not meet your needs and in any case is likely not easy to find.

Just the standard epoxy in the two tubes.

You can use JB weld to fill the gouges and sand them down. I've even done that on head gasket fire ring mating surfaces on engines. Customer was fully aware of the risk and "only" wanted another year out of it. That was about 7 years ago and it's still running.

There's three two way valves behind the driver's side step curtain. Look UP behind the step with the washer bottle. There is another one-way check valve right behind the glad hands. And there's a couple more one-way checks behind the service and wet tanks. Replace them ALL. They are cheap...

Yeah I wouldn't bother with any of that. Waste of time and fluid. Drain trans and transfer case. Change filters and fill with new fluid ( ATF - The Army uses Dexron VI ). Disconnect return line from cooler and run the engine till you see red fluid. Fill to capacity. Done. Don't pour any kind...

Test the batteries individually with them disconnected.

The military no longer uses 15w40 in the Allison's on the A1P2's. They use Dexron VI.

That is the IAP Solenoid (regulating valve) that goes into the pump, not the sensor that you need. C7 is the best choice and the newest - 2004.5 / serial number 100,001 and up. These trucks are known as "A1R" trucks although the data plate still says A1. The C7 was adopted over 20 years ago...

That's the IAP sensor that is measuring the oil pressure produced by the HEUI pump. Between about 500 and 3000 psi. Not really any good "cheap" options for what you are going to be most interested in since this is J1939 heavy duty world and even in that world the HEUI injection system is an...

..... based on the injector connector I think it's a 3126. Fuel system and high pressure oil system pulled apart..... smells like HEUI system problems which would make sense for that engine..... that seems to be a real common theme with them. I bet it wouldn't start so they were chasing fuel...

What year? Which engine?

That's a tall order also. Friend of mine had to replace his C7 - $35,000 at the shop in Denver. That's with a surplus crate motor not one from CAT ($55k from CAT was the estimate) - and that's not considering the changes required to move from a 3126 to the C7 (should be minor though).

It's not fear mongering - I work with FD trucks also and if he can get a C7 truck he should do it IMO. I would rather see them go to a rural FD than some of the idiot civilians that butcher them. I'm not a fan of 3126 trucks personally. They are responsible for the majority of the engine repairs...

Have to weigh it out then. It's going to be roughly $10,000 to fix just the engine on that truck if it needs a HEUI pump, main oil pump, oil cooler reseal with updated gaskets, HEUI pre-filter, and labor..... Another ~$6,000 for injectors if it needs those..... Not even considering anything else...

"But officer these bracelets don't match my....... OW! my arm doesn't bend that way guy!"