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It never worked right since I bought the truck, and I have just been ignoring it. However, I think I figured it out and I am embarrassed to admit it took me this long. The ground path for the blue wires on the side marker bulbs is THROUGH the park lamp bulb. This is why the bulbs flash at...

The bulb works in the socket on the other side of the truck. The grounds are good, and as far as I can tell there are no loose connections. The lamp is a single filament, 2 wire bulb and flashes when the turn signal is engaged. Unless I am overlooking something, this means the bulb, socket...

I've been looking at F-13 and F-14 in the -20 TM for about 2 hours, but I dont understand what the diagram is saying. All passenger side marker and turn signals on the truck work. The driver side parking light and rear turn signal works, and the side marker light flashes when the turn signal is...

Honestly, mostly superstition. I take this truck way out into the backcountry alone, and I can't run the risk of it breaking. I bought it in 2018 so it has 32 years of operational history I don't know anything about, and I think head gasket materials have come a long way since the 1980s...

Hey AFGVET, Congrats on getting your 1009 on the road. You should 100% do the A/C, it's definitely worth it if you live anywhere or ever go anywhere that's hot. I do still have a complete turbo setup off a 6.5 gathering dust in my garage. It'll go on someday, but I just don't have the time...

Supercharged 6.2/6.5 has been done, but not by me. This was an interesting thread a long time ago on the DieselPlace about this topic. Lots of interesting info. https://www.dieselplace.com/threads/project-supercharged-6-2.834001/

Sounds like the pinion nut backed off, and you kept driving. Applying throttle forces the pinion outward into the housing, and letting off the throttle sucks it inward. A correctly torqued pinion nut counteracts the load on deceleration, and when it loosens the gears come out of mesh and start...

I have the Rockauto pump and a Rockauto aluminum radiator in my M1009. It provides plenty of cooling. I have installed 3.73 axle gears and a manual trans, but hauling a 6000 lb trailer up into the mountains the coolant never got over 190F. Oil temp never got above 210. Foot on the floor in...

4l80 is a good trans for a CUCV. The splits in an the nv4500 with the super low first are similar to an sm465, and I agree they are poorly suited to a low RPM diesel. I have a truck with a 5.7 gas motor and a sm465 (no overdrive) and it's great, but that engine makes power out past 5000...

What overdrive do you have? I have an SM465 I swapped in along with an Advanced Adapters Ranger overdrive unit. It's a 2 speed manual transmission that goes in front of the sm465 4 speed and allows splitting each gear. The "8 speed manual" is a blast to drive, and cruising 80 on the highway...

My pulley info is here. I used a full set off a HMMWV (crank, water pump, power steering) to get the 4th groove. That thread has a link to a write up with pulley part numbers and such, but let me know if you have any other questions. The AC swap is definitely worth the effort and cost...

They should be 3/8-16. Maybe 5 on each side, and 5-6 across the back of the cab roof? You should be able to count the number of holes in the top or the bedsides to tell for sure.

Well, the Humvee pulley set works. The water pump pulley comes with a mounting boss for the Humvee fan clutch which is not correct for a CUCV. You just have to remove this boss and machine a counterbore to accept the CUCV fan, or I suppose you could run a Humvee fan. Also the spacing off the...

If anyone is interested, this is how I ended up building the setup. I put the compressor on the driver side with a custom bracket off the alternator. This retains the factory 24 volt system, avoids my electric air compressors already installed on the driver side, and leave the entire passenger...

Advance Adapters manufactures an aluminum case 2 speed transmission (.73 OD and 1:1) that mounts in front of the SM465. I run one in my m1009 and it works well. You can split all gears in 4wd, 2wd, low or high and it is very useful off road to keep the diesel in it's power band. With 3.73...

I have had the noise for 3 years on a junkyard trans, and when I pulled it everything was in great shape except some wear on the leading edge of the reverse gear, which I expect in an un-synchronized gear. Still has the noise after rebuilding. No apparent damage, but it is very annoying.

Sorry to bring this back from the dead, but did you ever figure out a fix for the rattle? I have the exact same rattle (video link at the end), and am wondering how you dealt with it. I've always this rattle/grind at low RPM that sounds like the engine pulses are causing the gear teeth to...

Haha ok. This is not a solution I am going to implement, though I appreciate your suggestion 🙂

Thanks for all the input so far. With the engine off and cold, I can spin the fan easily by hand. I assume this means the clutch is not locked up? The engine starts and runs well for what it is, so I don't think I want to just pull it out blindly. I'll purchase a diesel compression tester...

Well, I am not sure what to try from here. I just replaced my thermostat for the second time with another Delco 132-55 (GM 14077122), and the truck still will not warm up above 160F. I have a Vintage Air system with a block off valve in the heater circuit, so there is no flow through the...