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The stock HMMWV has 4 radiators: One for engine coolant (the "classic" radiator we all know, an engine oil cooler and a transmission fluid cooler (these are in a combined unit that sits on top of the large radiator) and lastly a power steering fluid cooler (that's the little one 3" thick that...

Appreciated, and agreed, but this engine has never been great. It's leaking from every seam. Better to replace than repair at this point. I got maybe 3000mi on it after it was swapped in. I'll have to do a better job with the replacement. BDGR

Well today was a bust. It started well. I met my neighbor’s two teenage sons who are in auto technician school and gave them lots of instruction about HMMWVs. They were very helpful and we got the hood off and began tearing down the cooling stack to get my radiator off to pressure test. Then we...

Here are some field photos of the new prototype mounted on my truck. I need to tweak the forward fitment, but the rest wasn’t bad. This cover will need one more modification and then I can ship it out to my beta tester. The frame seems good. I’m still cogitating on the assembly instructions...

Many thanks for these details Cybul. We're going to have the cooling stack out, so we'll have decent access. I think a mount is cracked on my Champion radiator, so it needs to be removed for pressure testing and leak diagnosis. My challenge with the last attempt of a new tensioner was the new...

The cover and frame are complete. They look similar to the pictures given, so I’ll wait until I have on-truck photos to share. This will be going out to Texas soon to escape our unusually cold Virginia winter and enjoy some sun. BDGR

Looks good. Any tips for getting the tensioner in place given its strong tendency to want to push itself out of bolt hole alignment? I hope to be doing mine Sunday. Bulldogger

Looks fantastic!

Here is the finished Gen 3 "humpty-back" cover. I am sealing the seams on this one, to see how it performs. I've not had seam leaks reported to any great degree, to any great degree, but wanted to explore it. Will finalize the frame design this week. The existing frame on the assembly jig is...

Welcome to the site and to the MV club. The folks at Ft. Meade DLA when I picked up my HMMWV 8 years ago were pretty easy to deal with. They did not allow driving off the base at the time. Obviously, the safest position about driving is to assume it's NOT ready to go. As far as legal driving...

Until I have this mounted and outside I won't have a good feeling for whether windows are still practical. Certainly one in the center panel will have a bar running through it. I do like being able to see into the bed from the back though. In my own ride I mounted a rear view mirror too. I'll...

I'd appreciate feedback on this new look. This is a rough cover for the "humpy" frame. One is in 1000D Cordura nylon (that soft slant back kits used to be made from) and one is a prototype in mil spec PVC vinyl. I'm still figuring out how to sew this to completion. I thought it would be...

Some people have asked what a frame that more closely resembles the military slant back with the humped rear would look like. In response, I'm working on a new frame that will be a totally new design for the frame and cover. I welcome feedback on this idea. It is a bit taller on the rear end...

Here is what an existing cover looks like on that new frame design (spoiler: exactly the same as before, they are backwards compatible on purpose)

Bringing up this old thread with some updated R&D. There was another thread but it was closed after the site was upgraded. Here is a new frame design that uses stronger tubing and connectors. Clamps are screw in (repurposed electrical fittings) and bolted. If anyone knows an available...

Your plan to change all the fluids is a sound one. Note that the Lube Order includes checking the portal hubs and several other "odd" places too, such as the differentials. A drain and fill of the differentials is fine, IMO, but you really should make the time to open the geared hubs and inspect...

+1 feeds for radio tray. At least one of those wires is HOT 24VDC all the time. Be careful. Best to disconnect and remove them all and blank off the hole, unless you have another use for it intended. BDGR

Welcome Abram80. There are many HMMWV owners in NOVA. There is also a Nova HMMWV owners group on Facebook, if you are on that platform. There is, or was, a repair shop in Richmond that took in HMMWVs as well, if you are not up to all the wrenching. Welcome again and please keep us posted on...

Folks seem to be experiencing varied results. Please let us know how your efforts turn out. I am still waiting to attempt it myself. BDGR

Well, according to those 1980's G.I. Joe Public Service Announcements "Knowing is half the battle", so you've got that going for you. BDGR