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The shifter will fit, but the detents are evenly spaced for the 4L80E and are not on the 3L80 so it won't work perfectly.

That nipple where the fuel return line you mention can be a problem. It has a glass plunger inside with a spring as well. It can get jammed with bits of deteriorating fuel return hose particles and if it is stuck closed, it keeps the mechanical advance parts in full retard. Might be the problem...

The fan is locked and unlocked to the water pump shaft at the front end of the assy, The rear part with the phenolic friction part is there for stabilization and to allow the fan to slip in relation to the water pump shaft without flopping off balance. The fan doesn't stop when de-activated it...

You may as well check the grounds on the engine wire harness and main body wire harness while you are at it.

That doesn't sound like a rod knock from either end of the rod.

Might be a bad Idler Arm.

I just went aboard a ship for Fleet Week in San Francisco and of the three USMC Humvees that I saw, one of them had the push button switch so they are in use.

A C Series would not have been owned by any part of the US Military so no EUC is required by the US Military or it's Government or it could all just be part of one large conspiracy against each and everyone.

The Humvee pump had a special impeller so maybe if shopping for a water pump and not getting a Military Pump, look for a high flow version if it is available.

Well, that water pump needs changing again anyway, even if it wasn't the cause. Can you see any marks on the fan shroud that would have been where all the blades might have made contact? It's impossible or near impossible to install the four allen head screws that hold the fan clutch in place...

I don't think so. I remember there being slight differences in the crankshaft dimensions. You should be able to find the exact info with some internet searching.

Very slight difference in stroke if I remember correctly, but all 6.5's have the single rear main seal and only the very late 6.2's use it. The other 6.2's have a upper and lower rear man seal like cars of old.

I made a three inch lift myself, but I had to move the hole where the steering shaft passes through the body tub. Two inches might allow you to only have to re position the boot. I went to a metal fabricator and looked through the scrap area where they saved bits and pieces and found an aluminum...

You need to use an injector pump for a turbo application as well as the injectors. Injector lines from a 6.5 Humvee engine N/A or Turbo will work.

OH, OK. Probably easiest to get a parts list or parts manual for a 1992 to 1993 Hummer and find what parts are the same. As you have found out, a military Parts TM doesn't give you easy part numbers to use. You will then be able to use the AM General civilian part number for the Hummer part in...

Call Kascar. They should have whatever you need and can get what they don't.

The 4L80E that AMG put into the Hummers was an RV Spec Transmission. I'd guess there are some differences inside to make them handle the higher vehicle weight, but any other 4L80E will fit and work as long as you have the right torque converter for the diesel engine. They moved the trans cooler...

The three speed trans has uneven detents and so does it's shifter. The four speed trans has even ones and so does it's shifter so you can use it to shift a three speed trans, but you have to go by the feel of the detents that are inside of the trans, because they won't all match up to a detent...

The 4L80E will bolt directly to the 6.2. The flexplate can even still be used, but because they do crack and they are under $100 I would install a new one while the trans is off. The same flex plate is used on both the 6.2 and 6.5. Unless you replace the timing chain and sprockets to one from a...

Check and clean all of your ground connections on the vehicle. Things might work perfectly after that.