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Most will tell you to take this opportunity to replace that 400A with a 200A alternator. The 400A alternator is considered undesirable because of it enormous weight and mass makes it hard to work around and the mounting bolt design is insufficient for such a heavy alternator. I have a solid...

I would look at the back of those headlights and see if they are 12V if he re-wired the headlights for 12V that is your problem, the 12V lights pull around twice the amps as the 24V ones which would overload the breaker.

Have you removed the two check valves in front of the fuel tank? they are problematic and most just remove them. Was it running OK before you changed the filter? if not the lift pump could also be bad, the engine will usually run but not well with a bad lift pump but the pump in the IP will not...

There is a circuit breaker in the light switch, you must be overloading the breaker or it is weak. Have the headlights been replaced, or was it in civilian hands before you bought it?

OK OK I stand corrected, TWICE!!:cry:

With a 500K serial number it has gone through RECAP, they issue a new serial number and reset the build date, it is actually probably a 2005 or later year model. NOW if he can get that re-assigned to a 1994 or earlier that would be best but in reality it is no longer a 1980s/90s truck, and in TX...

I talked to the ladies down at the tax office, they see no way to proceed without some documented year of manufacture, said unlikely you will even be able to get it inspected as one of the requirements of the inspection is establishing the year model. She did however say she did not think you...

That big honkin starter solenoid pulls too many initial amps for a key switch and the reverse EMF arcs the crud out of those switches

Oh yes new information, get rid of that key switch, well known faux pas in the HMMWV world

I thought HMMWVs with generators in the back are fairly common

WELCOME TO THE FORUM!! If the engine is warm than it is not glow plugs, that sounds horrible when starting:unsure: I wish you had included a few more seconds when running, sounds like the engine may be timed incorrectly. The two things I would do is run a cylinder balance test, cracking open...

Yes that view looked familiar:giggle:

You have a 2" body lift?

No emission testing on any diesels in TX:cool:

I did, TRYING to move it up to first page now

Every newbie should read page 139, can save them big bucks. I read this somewhere else a long time ago, maybe why I have never replaced a glow plug. There is some GREAT reading here, thank you for posting!!

Welcome to the forum!!! Is it possible you got the wrong 90 deg adapter, something is reversing the speedo cable direction as the speedo should only work in forward.

Yep, know it well, my sister lives between Sabinal and Leakey, grew up on the north side of SA.

About 1.5 hrs south of you.

I believe that casting number has no bearing on what year it was built, I would go beck to GP and tell them they gave you paperwork that is worthless. All the trucks that went through RECAP were given new year models, it is likely a 2005 or 2006, but that does not help. I will be in town Wed and...