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I always start with a Basic or A1 truck as with the 4.97:1 final ratio on those trucks is more desirable than the 5.24:1 the 2:73 gears give IMHO On my Dmax install, with the 2.56 gears I am only turning about 200 RPM faster at 75MPH than I am on my 2008 3500HD tow vehicle. The 5.24 gears should...

Did you remove the rod and grease it or try to stick some grease on it without removing the rod? I have never had any issue when removing the rod and greasing it including the rod end where it contacts the cam.

The brake light is likely the brake proportioning valve, you can check this by unplugging the wire from the valve.

Sounds like you got the wrong pump.

I think sign wave is for DC/AC inverters only

You do not need the coolers, diff or transfer case unless you plan on going under extremely heavy load in low range in something like sand for a long period of time. Yes just about any 4WD 4l80 should bolt up, I was not aware of any cooler line differences, if your original trans is good, I...

This was an up-armored truck so it sits much higher without the armor so it depends on the truck, an old M998 with 35 year old springs and sagging body mounts will not likely have the clearance for the 39s

The shell around the radiator is steel not copper

That should be OK. You never said you replaced the filter, it is of utmost importance to maintain a very clean filter or the lift pump can push crap past the filter and plug up the IP. I never cared for canister filters, when I started as a mechanic many types of equipment and autos had canister...

If you disconnect and connect the wire #54 at the front of the IP do you hear the solenoid click inside the IP? The other wire is the cold advance, working or not the engine should still start. Just keep trying, sometimes the plungers in the IP get stuck, good hot batteries and a fast cranking...

Sorry, I did not pay attention to the flywheel other than inspecting it for serviceability :(

Welcome to the SS forums. Look at the post right before yours. #180

That makes no sense if you use a new gasket, but as I said whatever gets the job done, as long as you are aware of the issue.

I am just not sure why so many resist removing that plate, it is only two small screws and then you do not have to stand on your head, hold your tongue just right and worry about getting the rod out of the way, seems like a no brainer every time I do it, but whatever gets the job done;)

Actually not exactly the same, if you look you can see a 3/8" bolt in the block behind the harmonic balancer, that threaded hole in the block intersects the push rod bore, on all the GM gassers you simply remove that short bolt and install a longer one and carefully snug it against the pump rod...

This is basically what you will be faced with, despite being a gasser the design is exactly the same.

Be very careful that you have the fuel pump rod fully seated in the block before installing the new pump or you will break the pump rod. I pull the small plate that is behind the pump held on with 2, 1/4" screws, then grease the rod with thick axle grease and re-install the rod, the plate and...

Welcome to the SS forums!!!

As far as the way the brakes are set up you have a perfect example on the other side of the truck. All power steering return hoses should be replaced with power steering return hose

Welcome to the SS forums!!! Probably a rebuilt engine, does it say Melton on the valve cover?