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M1009 starting problems

zyrtecx

Member
288
6
18
Location
Western NC
My M1009 that I got at Jefferson City, Mo. showed 35,000 miles and the glow plugs were Wellman, just ordered 8 new glow plugs from NAPA (AC 13 type) that have the correct connector... They are suppose the be here today.
I took the replacement glow plugs out of a M1009 that I had 91,000 miles showing, they were AC13 and looked really good and this M1009 had been sitting 2 1/2 years... Every one of the glow plugs in this vehicle were OK but rusty on the outside and no rust on the inside...
 

kipman

Active member
2,514
15
38
Location
Lancaster Ohio
I think breaking off the glow plug, removing the injector was very easy, I did this on 4 plugs and took 2.5 hours. I used a hemostat to fish out the broken tip.
 

cleb

New member
218
0
0
Location
Huntsville, AL
I had the same starting issue with my M1009....I put all new AC13G's (IIRC) in, and after a couple weeks ALL 8 were fried with swollen heads. I took all 8 injectors out, then unscrewed the glow plugs, and pulled them out as far as they would go. Next I took a pair of vice grips, and bent the head back and forth until it broke off. I then pushed the remainder of the glow plug into the head with a new glow plug. Be careful at this step! if you push it in too far, it will drop into the head, not good! When I could just see it from the injector hole, I grabbed it with a pair of Hemostats like Kipman mentioned. I did this with all 8, didn't drop a single one. I replaced them all with AC60G's, only way to go.

After that I still had a starting problem after sitting for a day or more. Turned out to be a combination of an old injector pump, with old cracked rubber hoses. I replaced the IP, and ALL rubber hoses between the tank and the IP. The truck started in 0 degree weather without issues after that. I also had a manual Glow plug switch on this truck, as the controller cards like to fry.
 
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