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The turbo exhaust gasket that CAT gave me was fully rectangular without the bolt "bumps" on the short sides. Probably irrelevant. Make sure it's got a fire ring though. It's going to see ~60 psi of pressure.

There's two of one gasket - block to spacer, spacer to cooler. And one of the divided gaskets - cooler to filter head/plate.

You don't have to pull off the oil drain pipe from the bottom of the turbo. There are a couple o-rings between the pipe elbow and the block though. You will need those.

The updated filter head/plate is one piece. Is the one on your truck though? The one we just did was not.

Here's the breakdown on the cooler. I can't pull up the o-rings on the two-piece filter housing - do you have a picture of your filter housing? Note the gasket and o-ring required quantities. 4 o-rings and 2 gaskets.

CAT Service Information System. You have to have a CAT dealer/corporate login to use it.

What's your engine serial number? I can lookup the part numbers on SIS.

For a one-off I would tend to agree and if the weight of the new alternator isn't crazy I'm sure that would work fine. The Niehoff 260 ( 72 lbs ) and the 300 ( 98 lbs ) are such that the inherent stresses and hardening in the weld areas cause failures. Yeah I know it can be annealed and it's...

Neither one. One has no filter head o-rings and the other doesn't have enough o-rings for the plates and spacers.

I think I have the invoice at my shop with all the part numbers we ordered. The picture you posted looks correct although it doesn't have the o-rings for the two-piece filter head plate. The exhaust manifold to turbocharger gasket is just a standard T3 turbocharger housing gasket (divided)...

The HIMARS bracket I showed above is the current version. The one in that Eastern Surplus listing is the old original 260A (fits the 300A as well) bracket from when the 260 was first introduced (and the one on my 2008 A1R from the factory) - the HIMARS 300A is heavier and it caused them to fail...

I would copy the HIMARS design used on the C7. Fits both the Niehoff 260 and 300 (98 lbs). Only welding required is the pivot tube which is just a chunk of heavy wall tubing.... I have a friend making me 15 of them. Way simpler and more elegant. One laser cut piece of steel, 3 bends, and four...

The turbo does have to come off. And the alternator. The cooler, spacer plate, and filter housing/cover has three gaskets (two are duplicates) and four o-rings. No sealant has to be used if you get the gaskets from CAT. Also CAT will not be able to find the three additional o-rings on the...

Lots of old school, old world methods available. Could scrape it the way lathe and mill beds were done 100 years ago. Or spend hours with glass and 120 grit fabric backed abrasive sheets (it goes up in grit as you wear it down). Actually use this method on aluminum cylinder heads all the time...

Adept Ape talked about them when he still worked for CAT and lamented that he kept getting reman coolers that were warped out of the box. We checked pricing and they are ~$628 plus a $298 core. Seems like a lot of money to potentially accomplish nothing. Decking the cooler at the machine shop...

Naw. It's probably ~10 - 15 lbs. Shipping probably $25 or less. It fits over the latch perfectly and the pin end is rubber coated. The right tool is available and for that price considering the cost of plate steel, cutting, welding, etc - not a chance it costs less than surplus.

Just did this job AGAIN on another 3126b truck (2002 with ~16k miles). Measured that new oil cooler gasket and the gasket thickness is 0.013", with the embossed sealing ridges taking that up to 0.020" so the gasket has the capability to seal 0.007" with the embossing - maybe a *bit* more with...

Not as far as I can tell for the 3126. I can't even find any disassembly videos of one. There are tool kits and rebuild kits out there as well as videos for the C7/C9 pump but they are COMPLETELY different in design. I have wondered if it would be possible to use the C7 HEUI pump on the 3126 but...

I think the fuel system is the least of your worries. The 3126b HEUI pump is a much, much bigger concern and when it fails (not if), you will be replacing the fuel transfer pump on the back of it (really simple plunger pump run by an eccentric skateboard bearing on the HEUI), and you may be...

That happened the first time I powered up my system too! I did manage to get it to stop fortunately so I could drive home from @Lostchain 's shop. PCU spool valves were contaminated with crap from the wet tank. They really should have given the PCU an inline filter so crud from the wet tank...