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Received my injector removal socket yesterday. A few things came up so I didn't get around to removing anything until today. The plan was to get these things pressure tested to see if they needed a rebuild/replacement. However, all the injector tips look pretty well destroyed so I think...

Per Barrman's advice, I gave just a little bit more wrench to the wet injector. Sure enough, that seems to have cleared up the pooling fuel at that point. I also took off the check valve on the Injection Pump. I used this thread to make heads and tails of where this infamous glass ball is...

I forgot to mention I tightened the steel line at the injector about a week ago with a 3/4" wrench. It felt pretty darn tight. I have not looked into the return line at the top of the IP yet. Is that where the infamous glass ball check valve is? I've read several posts mentioning this check...

After my test drive, popped the hood to check everything out. Again, the first injector on the driver's side appeared wet. It seems to have fuel pooling up by the steel line. It looked like there were tiny bubbling going on in the fuel puddle. I wonder if that #1 injector is stuck closed and...

I've eliminated the kink in the fuel line by the lift pump. I know the OEM part would have perhaps been better, but I needed some immediate gratification. I used two right angle brass fittings with pipe thread on one end and a barb for 3/8" I.D. fuel line on the other. I coupled them with a...

Hmmm.. I hadn't thought of heat shrink tubing. I was going to try to jerry-rig something similar with garden hose but it didn't work out so hot. I'm still considering the pressure gage, because I'd like to know for sure that the hose by the lift pump is the problem before I start tinkering...

After much thread searching, I think I've devised a sequence to troubleshoot my issue but I'd love a second opinion on my methods. I'd like to make sure I'm not doing extra stuff that doesn't matter or doesn't make sense. So a while back I had an abnormally large puddle under my M1009. I saw...

I second that one. Also the soft hose going into the lift pump.

How on earth did you figure out that was the source of the sound? I don't know if I would have ever thought to check that. I've got a similar sound, but I haven't gotten around to diagnosing it yet -- more pressing matters need fixing. I would describe my sound as there being an elf inside...

Bump. I'm having nearly identical issues. I'm about to try the snake oil and various additives...

Any updates on this one? Is you truck running better now?

Any updates or solutions on the lack of power? I'm kind of in the same boat myself...

If I recall correctly, the small black wire is for the STE/ICE unit. I don't think it's critical for proper function. That said, you probably want to verify that before chopping anything off.

My red-top optimas also work incredible. I believe they're 850CCA each. Between them and the rebuilt starter, she starts right up. From what I read, the optimas are more resistant to the vibrations you get with a diesel. They're definitely a bit more on the expensive side, though.

I'm just up the road in Eagan if you ever get in a bind. I've got a towbar 8)

The guys at Ft. McCoy were pretty decent (at least when I was there). The guy running the forks [that day] lifted on the transfer case brace and put blocks on the other fork to not mess up my driveshaft. Staff was pretty cool except they reamed me pretty hard about Bret Farve when they saw my...

You probably have a bit of a compound problem going on here: 1. You've got something putting out too much power or consuming too much power or a short. This is causing your wire to melt. 2. The fusible link in question is not working correctly. Fix both of these. For #2, someone my have...

Have you checked transmission fluid level? I had similar symptoms (minus the grinding sound) and it turned out that I was [embarassingly] low on ATF. As mentioned above, grinding sound makes the transfer case more of a suspect.

Was it possibly a poor ground between the starter and the engine block? Jiggling things around and retightening the bolts could rememdy a poor ground connection.

I found mine at O'Reilly's Auto. I listed the part number in the thread. I would try another parts store if NAPA cannot find the tool for you.