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Almost finished with the cold air side. Stock manifold modified for the compressor outlets. 1.80" ID spools fit into each bank for the O ring sealed tubes from compressors. Welds were difficult due to access and heat. Blew through 10 tungsten electrodes and still have half of the second...

Needed to balance work and get things made on the intake. Basically lifting the stock air filter 2 inches with a collar. The collar has a 1/4" plate on the bottom, gasket sealed and 4 bolts. Two are the air filter hold down studs, two more added by welding bosses inside each plenum. Filtered...

The plastic retainers yield to a good U joint press without heat. Don't do what I did and break a good vise. I found the proper press from a local scrap dealer for $20.

Certain pilot bushing removal tools will also work. 9 and a half dollars is a steal.

Fishing the seal out is easier with this tool: There is a sharp shoulder on the shaft which can cut the new seal. This is why he used that mylar film. Thin heat shrink also works.

The barrel needs to spring out when not energized. This is a fail safe mechanism but in your case, not so much. Easy swap.

The solenoid is ETR, energized to run. Which is to say a spring in the solenoid closes the metering valve when the current to the solenoid is stopped. I would say the solenoid, an electromagnet, is either dirty, corroded or in need of replacement. There was a design change in the 1980s to...

Tag and bag fasteners or have some means of organization. The intake manifold comes off easily. The gasket is probably bonded to the heads. Gasket removing spray helps. Stuff paper towels in the ports. Remove oil fill tube and grommet. I have a set of magnets which fit in sockets, these...

Sole purpose is to properly reconnect lines to the VRV.

Did it on my M1031 SECM as stock springs were sagging under load, plus abuse of towing 12k..with brakes, slow. I removed the helper springs, using replacement u bolts with longer threaded sections, then trimmed. Hole drilling wasn't too bad. Was able to mount the Schraeder valves between...

This is why I am doing the turbo before 4L80E transplant. It only adds 50 Hp but nearly 100 foot-pounds of torque. Engine torque curves track volumetric efficiency curves. Adding a turbo only changes charge density, the volumetric efficiency remains the same. Power is based on mass flow rate.

Per TM 9-2815-237-34, 13 to 25 foot-lbf. Make sure the covers are not distorted in the clamping area. This TM covers the HMMWV engine. Valve covers are identical.

The only sticking point is pre glow delay. The rest is academic. Most diesel remote systems have two way communication, better ones have a WTS light logic with tach sense. Plenty out there for specific models, I don't have time to research as this bit of kit has yet to tickle me fancy.

The injection pump in my 1031 is the DB2829-4520, calibrated for 48-52 mm^3 (microliters) per stroke up to 3600 RPM. It still delivers 40 mm^3 @ 4000 RPM. The problem is the engine breathing above 3600 RPM. Which means higher EGT and decreased thermal efficiency. Earlier pumps have similar...

GV OD would work on a 1008 but 1010 and any towing application would lose considerable energy in torque converter slip. Yes, the 4L80 requires electrical logic for full automation. It can be manual shifted via simple switches. With aftermarket controller, it is quite simple to get a modern...

3 inch diameter isn't enough? The 6.2 gulps 350 standard cubic feet per minute. At 10 PSI boost, that is 600 cubic feet per minute. A 3 inch diameter pipe has flow area of 7 square inches, at 600 cubic feet per minute, that is velocity of about 200 feet per second, a velocity less than...

The governed maximum speed of the engine is debated often..per the calibration on a DB2829-4520, the pump delivers maximum fuel of 48-52mm^3 at 3600 but still delivers 40mm^3 at 4000 RPM. At 4400 RPM, it should be nearly nothing @ 8mm^3. Since this is the pump in my M1031, I can attest it will...

Should be quality. I always had issues getting grease to all 4 cups, the ones that fail were always dry. I even bought a quality press as I was doing it so often. Managed to find Spicer joints and no more failed joints.

Hopkins Agility 47295. I integrated it into the NATO trailer electrical connector, then made an adapter to 7 pin with an old military trailer plug. Never had any real panic stops. Tests, sure.

Crusty. Use quality parts, I have been there many times because of cheap parts.