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The repair parts are also made overseas these days. You may not believe it but they can make defective bushings for the 27MT. The specs call for OD, ID, length and material but they will try to make the ID larger than the OD ;) Ok, that is over the top..but I had wheel cylinders that I spent...

The starter might be incorrectly assembled. Or incorrectly adjusted. The pinion should nearly touch the inside of the nose cone bushing when the Bendix is at full pull travel. Other thing would be the Bendix solenoid could be faulty. There are two windings, the pull in and the hold. If it...

It is cast aluminum. It can be welded. I did mine some 6 years ago. Still chooching perfectly. What happened was someone forgot to install the pinion retainer and it beat the nose to death. I tacked the fracture, then vee grooved both sides to get skookum penetration. 4043 filler, GTAW...

It took me 30 minutes to overhaul each alternator, including bearings and bandaging my finger. Just be careful driving bearings out. I've sourced domestic bearings too. The only issue is the aftermarket regulator. Had one fail, causing over volt, blown diode and thrown belt..probably...

Most older Delco parts are now made in China. The solution is to rebuild your originals, not hard to DIY starters and alternators.

Shims on starter to block increase pinion to ring gear clearance and are usually not needed. This clearance is checked by disconnecting the big fat wire to the starter (24 volt on stock CUCV) and putting 24 volts to the small terminal on the starter. This engages the Bendix without turning the...

Looks correct, the pinion slides on the starter shaft by action of the Bendix solenoid mounted on the top of the starter. After the pinion gear meshes with the ring gear, the contactor section of the Bendix then energizes the starter motor. No click under the hood means no Bendix solenoid...

The CDR uses the air filter restriction induced vacuum to induce a 5 inches of water vacuum in the crankcase. This is less than 0.20 PSI vacuum. Tiny. The real purpose of this vacuum is to draw air into the oil fill cap(there is a filter in there, hence its shape) to keep blow by gases clear...

Factory specification for crankcase vacuum is 5 inches of water at 2000 RPM. A dirty air filter could restrict air flow, causing this vacuum at lower RPM. No throttle in a diesel intake so air flow is engine speed dependent. When the air filter clogs, the CDR prevents excessive vacuum in...

The CDR keeps the crankcase at a very slight vacuum AND induce fresh air flow through the crankcase to keep blow by humidity from spoiling the oil. Fresh air enters the crankcase through the oil filler cap. Also engine crankshaft seals can weep with excessive crankcase pressure. On turbo...

Wow. Lesson learned at a high price. I would recommend downloading the technical manuals and learning how these vehicles work. It isn't difficult, all the help needed is here. If you cannot find it with a search, ask away. We are mostly friendly and will get you on the right path.

My diesel burning Kraut rocket (I'm half German, I have license to use that term) has a large filler neck too. I've used truck pumps. Fills up in 5 seconds. Back to military fueling, the M 49C had nozzles a bit larger than commercial truck pumps. The 5 ton tanker trucks, made with a fold...

That looks like aviation use. Every fuel tanker I filled from had the jumbo nozzle, anything under 50 gallon tank was filled by gravity as it was far below the tanker level. Earth moving equipment sometimes required pump operation as the tank could be higher and some were very large, like Cat...

To find the parasitic drain, rule out the fuse circuits by pulling fuses one at a time, then using a voltmeter set in the amperage measurement mode as the "fuse". Do this key off. There are a few diodes in the circuits which could draw a few miliamperes in reverse bias.

Blackout marker and brake lights. These are LED. The front drive light over the bridge plate holder is the blackout drive light. These are 5 MPH max speed lights, only useable on moonless nights.

Plenty of weld up universal kits from performance stores. The problem with stainless steel welding is you either must back purge with argon or paint the inner weld area with Solar Flux B. Chromium depletion from oxidation makes the weld rust faster than plain carbon steel.

I've used a pop rivet to replace the broken plastic part. No longer have that 1009 so no pictures.

Zip ties and PVC insulation do not play well together. Why? PVC is a rigid plastic, think pipe. To make it flexible, oils called plasticizers are added. Zip ties are nylon and can leach out these plasticizers, making the insulation brittle.

I was over 16,000 pounds combined at the dump one time. Never got above 45 MPH. 1980s era turbos start spooling at 1800 and get meaningful boost at 2200 RPM. The problem is the 80 cubic millimeters of diesel each time a cylinder has a power stroke when you don't have enough air. Smoke is...

No. Texas has mountains. Steep climbs