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The driver's side alt is unmodified. I made no modifications to the CUCV wiring harness. As a prefice, I generally source materials from McMaster-Carr as I use them daily in my normal job. I drilled out the passenger side alternator and sleeved it with some nylon air brake tubing. I used...

It was the latter set, I think 1996+. The specific truck it came from was a 2001 C3500 with a single alternator mounts on passenger side. There is an additional bracket necessary for the second alternator, these guys are making a reproduction of it. The setup also supports A/C. The serpentine...

Ospho turns the 1980's vintage CARC turquoise. Phosphoric acid etches polyurethane paint in general. I have my tugboat fleet using citric acid instead. It's a better daily cleaner. It doesn't have the rust conversion properties phosphoric has. Use Ospho between coats and citric for your regular...

Very interested. I put a dual alternator serpentine setup from a 2001 C3500 in my M1008 CUCV. I used standard CS130 alternators and sleeved the mounting holes to isolate one. Not ideal but it works. There are pigtail adapters so you don't have to cut your stock harness and the gen lights will...

During oil starvation the mains fail first. The rods are fed from the mains but the cross drilling works as a centrifugal pump to keep the rods fed while starving the mains.

I've seen that hose material before. It will be hard and full of cracks within 10k mi. Look at the lettering on the hose. If you see NBR, that's nitrile rubber and it doesn't tolerate the heat associated with injector return lines.

That indicates water in the fuel. The old Detroit Diesel or Electromotive trick was to use methanol to free up stuck pumps. Of course these were unit injectors.

Sandia National Labs did some examination of failed Stanadyne DB2 pumps after the army switched from diesel to JP8. They found that none of the failures were due to lack of lubrication. In my more modern fleet, the only wear-out failures were on Denso ECD-U2 pumps which occurred at 18,000...

I did a lock cylinder in my 1976 truck some years back. There is a thin spot in the column casting that you hammer a screwdriver through to get access to push the spring loaded retaining pin.

SAE o-ring boss plugs are always difficult to break loose. What brand of wrench were you using? There is huge variability in hex key quality/performance.

Roosamaster became Stanadyne. Very common pumps. It's not cost effective to rebuild a seized pump with new parts. Generally the pumps all have similar internals with different housings between models. If you can't find an identical housing you may find compatible internals.

Put your volt meter on each battery while cranking. If the battery voltage drops below 10 volts, the battery is toast. How old are these batteries? Can you see any bulging of the sides? Feel with your hand. Any bulging at all is bad. Each battery can be tested individually.

It is my understanding that a thinner oil will help prevent shoe lift.

I have not been able to determine a cause of failure for this one. There are no signs of shoe lift. I'll dig deeper for the pump that did fail due to shoe lift.

There is a spring that holds the shoes and shoe retainer against the swashplate. If there is sufficient pressure in the case of the pump or sufficient vacuum on the suction the pressure can overcome the spring which lets the shoes lift off the swashplate. When they come back down they contact at...

I don't know how the pump being larger would make it better. The C9 Cat engines with HEUI did have a recall because one of the bearings in the pump was failing. With regards to axial piston pumps restriction on the case drain or suction can cause shoe lift which destroys the pump. The second...

The John Deere engines are not intended to be checked while running. Engines that are will have a two sided dipstick with running and stopped levels. I do have a 4045 engine in my fleet that pushes oil out of the dipstick if you pull it while running. There is nothing wrong with that engine. Do...

Even without glow plugs the engine should smooth out within a few seconds if you're above 40°F. That engine is making some unhappy sounds but they don't sound like bearings but there is something seriously wrong with the engine. Is it blowing bubbles in the cooling system? Have you done an oil...

I forget if the tube is 1/8" or 3mm. Everything else is metric so it must be, right? 3mm will fit a little tighter.

Look into Donaldson Power Core air filters. There is nothing close in terms of performance and capacity. They have housing available with turbine separators to drop out the bulk of the dust.