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When you do one of these two-piece rear main seals, where to you locate the joints? It seems to me that if the joints were even with the mounting surface, that it could leak there. Or am I over-thinking this and it just really doesn't matter?

I had to use heat to get mine loose.

The glow plug system trouble-shooting guide in the -20 TM might help narrow down the problem, before having to buy parts...

My guess would be that it is the wire goes from the seat belt switch to the seat belt reminder buzzer.

Check grounds at each light, all of them, not just the one in question. Also carefully check the bulb sockets, as there is a ground tab in there that is known to corrode and break. Replacement sockets should be available at most auto parts houses.

Maybe the card is doing an after-glow cycle? Perhaps the temp sensor is bad, making the card think the engine is still cold?

Replace the return line on the IP with a clear fuel line, then you can look for air bubbles. Also, while you are in there, you can see if the return check valve is clogged.

Baring finding the problem elsewhere ( u-joints, correct fluid, etc ), perhaps get a spare transfer case and rebuild it, then just do a swap in an afternoon.

Is the switch in the 'service lights on' position? If not, no lights, or horn either...

I'd check the u-joihts at the front hubs, perhaps one, or both, are frozen or binding

No, it is not needed.

They were not part of the CUCV issue, so that was either added at the unit level or by whoever had it after it left the service, so that is why it wasn't in the TMs.

Have you pulled apart and cleaned the bulkhead connector? Perhaps there is a bad connection there...

If that happens, check the classifieds, I'm sure someone around here has surplus air, though most of it is probably hot... :-)

Maybe this will fix it?

And then a good coating of dielectric grease to finish it off..

Have you pulled apart and cleaned the bulkhead connector on the firewall? Almost all the connections between the engine compartment harness and the fuse box / dash harness go through there. After all these years, whatever GM sealed it with turns to goo. A good cleaning and some dielectric...

What is it doing when it has the shifting problems? Aside from issues inside the trans, the system is pretty simple. There is a vacuum pump on the back of the engine that provides constant vacuum to the vacuum regulator valve on the side of the injection pump, which controls the amount of vacuum...

Are you buying parts for an '86? All CUCVs are based on '84 parts, and that is where you should start. There are very few exceptions to this, like the seat bases in the later M1009's.

The procedure is spelled out in the -20 TM, which is available in the TM section of this site.