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None of those are going to be good structural solutions long term. The blocks crack at a critical stress point, where the engine bolts to the transmission bell housing. If you plan to do anything other than driving it to a repair facility, or maybe just parades for the rest of its life, you're...

That's exactly how my block cracked. There are a lot of people parting these out now, and you should be able to find an engine for it. Make sure to get the driveshafts balanced before you put the new engine in.

There was one on eBay for $1500 Buy It Now last year, also new in crate.

I'm not sure who "Jack" is, but that is poor reasoning. Yes, the government applied an upgrade to the all of the trucks in the late '90s, and yet we're seeing these problems so it clearly isn't a permanent fix. We have several users, including this thread and myself, that have destroyed their...

Where are those pictures from? I wonder what the parasitic energy to drive the fan is, when it is turned "off"?

This is true, but "non-modern" diesel engines aren't way worse. (What does "modern" mean, as even the 3116 is attempting to do some of the "modern" things they are describing in cruder, more mechanical ways.) Our engines are probably only 5-15% worse, so you're just gaining a little bit, and...

You won't get 25% improvement from any engine change (only). 5% is more likely, with 10% being a stretch goal. The engine isn't really the problem (largest contributor of waste), so changing it doesn't make a lot of difference. The "heavier things getting better MPG" are significantly...

My guess would be that Jeep shaft is just a different animal. On smaller vehicles, there are a lot of parts and options out there to cobble together something. With these, there is only 1 medium duty truck on the road for what, every 10,000 consumer vehicles sold? So there are going to be far...

Another thing I've forgotten to mention about my driveshafts is that the rear one had cardboard in it. The driveshaft guys said it's called a "tube deadener", and is intended to reduce vibrations. They took it out of my shaft, and did not replace it because they said it shouldn't be used on...

I'm really sorry to hear that, truly. Replacing the engine is expensive and very time consuming.

Ok, so "loose bolt", but how do you explain the bolt working loose? As you've said before, the alternator is a static part, so vibration loosened the bolt seems a likely explanation. Your second paragraph argument really isn't logical. "Why the water pump and not the starter?" Simple...

If that was the only issue, maybe, maybe not. But in the larger context of your alternator and fan issues, I would flip that question back to you that you would think it's a coincidence that some of the issues were related to overheating, but others (e.g. alternator bracket) were not? Driving...

The military studies answered that question in depth, with pictures, when theirs cracked exactly like that after something like 80 miles into their test. How much pressure do you think it takes to crack that aluminum cover? It's about 1/8" thick. It would take probably a couple hundred PSI to...

My "cover" is what cracked. We're talking about the same thing. I replaced the cover (which I have been calling housing to differentiate between it and non-waterpump parts like hoses and fittings), and then broke a bunch more stuff after that. Also, if you are convinced it's steam pressure that...

You have the exact pattern of symptoms, including cracking the water pump housing, as the military studies and other posters (including myself). You ultimately won't know until you get the driveshafts checked, or break more stuff, but the logic favors you having the same vibration problems, not...

Mine was exactly that, frozen and broke. What I did was hit it with a hammer to break it free, and then I used a large/thick screwdriver to reach in the hole and pry against the head of the screw in order to rotate the clutch housing until the bolts lined up with the holes. It worked way...

Not much to it. You open up the tire, and put a bunch of airsoft pellets or ball bearings in. I think the number thrown around is 1oz of pellets for every 13lb of tire, which means if you use airsoft pellets you need a lot of them (1/2 gallon?).

Technically yes, however I don't know how hard it is to change. I haven't messed with these axles, but when I rebuilt the rear 1-ton Chevy axle the nut on the yoke was very difficult to get off (it's like a 1" nut on the back of the pinion, and it's torqued to an incredibly high value, and...

Which bushing are you talking about? The large steel "roll pin" / split sleeve bushing in the rear bottom ear of the alternator? That's the only bushing in any mounting holes on the alternator or brackets on mine. If you were missing it, you would have big problems. It not only makes the...

Yes, though you'll have to replace the yokes on the transfer case and axles, I think.