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3 years later the tach finally quit working. I decided to tackle it now since I think I have a low-idle problem to troubleshoot. Running through the TMs diagnostic instructions, I determined that the tach was okay and the induction sensor was dead. I think I see why it quit working... It was...

I definitely count - unlike the Army I can't afford to break anything :p

I've never started a multifuel motor - I have an M35A3, which has the stright-diesel Cat 3116. That starts instantaneously for me on days where it's 55+ outside! The multifuel TM says to not crank for more than 10 seconds: Based on that I'd say if it takes more than that to start the truck...

I know this is an old thread, but I've been looking up stuff about axle seals and wet bearings and couldn't let this question go unanswered. If there's oil in the hub, it will get into the CTIS components and gunk things up. That leads to wheel valves not functioning correctly. If a wheel...

You could just drive it with the windshield down - one problem solved!

Are you going to be trashing steering knuckle boots enough to need those? I'd consider getting zipper boots and replace them as needed.

Nice to see you got the swap done! I find it interesting that the Army had TM instructions for such a swap. I bet they anticipated a 1545 shortage considering how few of the trucks were built compared to other trucks, and knew that no more were being built since the 1545 seemed to be a custom...

Big Mike's sells them for $2.50 USD each: https://www.bigmikesmotorpool.com/products/right-hand-lug-nut-for-front-wheel-or-single-wheel-m35-m54-m809-m939-ms51983-2?_pos=1&_sid=f55365e8d&_ss=r They'll ship to Canada, too.

I learned something about using the hollow stud as a clue about gear oil in the bearings. I have my CTIS wheel valves removed for now and have brass pipe caps on the hollow studs. Three rear studs dumped a lot of gear oil and grease was washed completely from the outer bearing. The fourth...

What are holding on your existing shields? Mine use right-hand thread wheel lug nuts, the same holding the wheels onto the truck.

The CTIS will work as long as there's space in the hub for air to flow from the inner wheel bearing into the hole in the side of the hub that's piped into the hollow wheel stud. It looks like you'll have to modify or fabricate stone shields to fit around the lockout hub. You can probably do...

That's super-important - thanks for mentioning that :) I really didn't know what the stock transmission was rated for.

I was thinking about a 2:1 reduction gearbox between the Vortec and the original 5-ton transmission. We'd be seeing up to 760 lb-ft at the gearbox output. Does a reduction gearbox like that exist, or would that be a custom component? Would that much torque break anything on the driveline...

What happens there? They're used in the GM pick-ups and full-size vans. Here's a comparison between the L96 Vortec 6.0L (for greater than 10000 lb GVWR trucks, or is it GCWR?) and the Continental R6602 (From TM9-2320-211-20): Attribute GM L96 Vortec 6.0L Small Block V8 GM L18 Vortec 8.1...

I've pondered this ever since I looked at an old tractor wrecker with a bad Continental motor - has anyone done an LS swap with a 5-ton gasser? I think the Chevy 6.0L Vortec has the same or better horsepower and torque than the old Continental motors. I'd consider trying this if I found a...

At least you have a cold air intake if you ever decide to do something like an LS swap!

How big is the condenser?

This is the first time I've performed drive hub maintenance on anything bigger than a Chrysler 200, so it's been a fun learning experience! On my second hub I got unlucky struggling to get the axle shaft seated in the differential (I got it on the first hub I did but had no clue how :p ). I...

Have you decided what's going on the back of it? Another wrecker body, perhaps?

The trucks typically take DOT-5. I think there might be a bleeder on the air pack too, but I say that having never done brake work on my truck. Someone else here might think of other bleeder locations.