Refreshing Gunny the thread.

[GunnyM1009]

This photo was taken in 2017, not to long after this the transmission went out on Gunny. Me not having the knowledge or the money to do anything to remedy the situation he got parked till late 2021 when I decided to just try to get him fired up and running again. After pulling glow plugs I put transmission fluid in each cylinder and let it sit over night. To my surprise he wasn't even the least bit seized when I put a wrench on him and turned him over. I then hooked up the batteries and turned him over with the starter to blow the trans fluid out. I installed new glow plugs and turned him over again and he tried to come to life immediately. That's when I decided this M1009 wants to be back on the road and this will be the build thread for that.

Edit- My name is Richard the truck got its name Gunny from a Marine friend of mine.

 

[GunnyM1009]

The first thing I had to do was get the transmission rebuilt. After attempting to call in some favors and all of them falling through I ordered a work bench how to on rebuilding a GM TH400 ordered the parts and few special tools I needed and set to work. This is the completed rebuild. all in I have about $650 in the trans rebuild and that's with buying the few tools I didn't have.

 

[GunnyM1009]

After I got done with the trans I remembered that the transfer case used to have a problem falling out of 4 high so I decided to go ahead and rebuild it as well with a new chain, bearings, and seals. Here is the completed transfer case. I think it cost about $250 with the new chain. and yes I rebuilt the trans and transfer case on that old ratty fold out table that I picked up off the side of the road. It does have some 1x4s screwed down across the center for a little added strength.

 

[GunnyM1009]

I decided before I put the trans and transfer case back in the underside of the truck needed some love so I commenced with degreasing and painting the under side. Fortunately I live in the south so no worries about salt down here. This should last many years to come. I also installed that new flex plate around this time with ARP bolts to hold it on.

 

[GunnyM1009]

I decided everything that got pulled off was either getting replaced if needed or at the very least a wire brushing and a coat of primer and paint. refreshed cross member with new grade 8 hardware which everything I replace will either have grade 8 bolts or ARP bolts.

 

[GunnyM1009]

While I have the rear wheels off I figured some rust removal and a paint job was in order for them as well. This is the first one completed. I will be doing the fronts when I start on the front end as well.

 

[INFChief]

Like the Energizer Bunny you just kept going & going & going & going! Looks great!

 

[GunnyM1009]

I pulled the fuel tank to clean it out and so I could degrease and paint the rear. So after I cleaned it out you guessed it wire brush and paint. I am currently waiting on a new sending unit, straps, and an anti squeak kit to come in from LMC.

 

[GunnyM1009]

Like the Energizer Bunny you just kept going & going & going & going! Looks great!

Thanks I am doing so much to it I figured a thread was in order instead of random posts here and there.

 

[GunnyM1009]

In case anyone wants to know this is the to do list for this build.so there is much to come.

 

[GunnyM1009]

While painting between the frame rails in the rear I noticed someone had pulled the loom off the wireing to the rear and a couple of wires had some small bare spots. I taped up the bare wires and put new loom on them.

 

[cucvrus]

You do know that clip in the frame was placed there to hold the wiring harness in place. I just noticed that the pictures show the harness unattached to the clips.

 

[GunnyM1009]

You do know that clip in the frame was placed there to hold the wiring harness in place. I just noticed that the pictures show the harness unattached to the clips.

Absolutely, I took the photos just before I wrapped a few pieces of tape around the loom and put it back in its clips.

 

[Mullaney]

Absolutely, I took the photos just before I wrapped a few pieces of tape around the loom and put it back in its clips.

.
Your truck is looking Good!!
Lots of work and the best part is that YOU did it.
Somehow that just makes the smile that much bigger as you roll down the road...

 

[GunnyM1009]

.
Your truck is looking Good!!
Lots of work and the best part is that YOU did it.
Somehow that just makes the smile that much bigger as you roll down the road...

I appreciate it. I'm currently 34 and my nephew has loved this truck since I got it when he was 13 I'm hoping to be able to leave it to him one day many years from now.

 

[GunnyM1009]

Got the fuel tank skid plate wire brushed with a coat of primer today. I probably won't get much done this week between rain and being on call for work. There's not going to be much spare time.

 

[ssdvc]

Gunny, when you rebuild the transfer case, did you replace the shifter shaft seal? How was that accomplished? I am asking because mine is leaking (the last leak I need to get to!!) and I want to fix it. Thanks!

 

[ssdvc]

Oh, I have an NP208.

 

[cucvrus]

Amazon.com: PMD Products GM Transmission Shifter Seal Remover Installer Turbo 300 350 400 700-R4 4L60 Includes Seal : Automotive

 

[GunnyM1009]

Gunny, when you rebuild the transfer case, did you replace the shifter shaft seal? How was that accomplished? I am asking because mine is leaking (the last leak I need to get to!!) and I want to fix it. Thanks!

CUCVRUS answered your question. With that tool you can remove the bolt that holds the linkage to the shaft and get the seal out and back. Otherwise you would have to pull the entire thing apart. that large flat piece on the right is the shifter on the inside and to get it out the T-case has to be almost completely broken down.