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I would think exhaust brake would work well enough without locking the converter, especially if he’s running low range. With our weight and gear ratios I don’t think a pinion brake would last more than one application, unless you ran a half dozen or so to keep the pressure down on them. I’m...

Pacbrake is probably the most common exhaust brake, a lot of info on them in the rv forums. I believe you will need heavier valve springs as well, which I was planning on going to one of these day if I turn my governed RPM up quite a bit.

So, with the u-bolt nut broke off, was the axle still secure, or was it shifting around? If moving around I would say that broke the cylinder, if not I would guess just stressed from the road conditions, and finally let go with a large impact to that tire. I’ve always wondered... How big of a...

Good read on transfer case breakage theories. I almost stalled my transmission completely out, 1rst gear, low range, wide open throtle, dragging my 25 ton loader up out of a mud hole with a thrown track and fortunatly did not break mine.

Looks like you figured out the photos, keep them coming! The torque rod bushings just get old and pop off under stress, I have never heard of transfercase range, or travel direction having a major effect on when they pop, but once one goes the others usually are short to follow. If you have...

Yes, if he wants to build a truck that all would be nice, especially a stronger transfercase, manual trans, and an engine brake or retarder.

I think with a little patience and maintenance, you have the perfect truck for the job! You can buy and press just the bushings in yourself, and you might as well replace them all and hopefully not worry about them for another 20 years. There is a good thread on the replacement here, but I...

Except the transmission... Running hills that pull you down to first gear, watch your transmission temps at 40,000lb+ gross weight. You may have to go down to low range with the transfercase if your hills and road conditions are as bad as I suspect. Also don’t lug the engine, keep it cranking...