Therooster2001's M925A2 build thread

[therooster2001]

Howdy all. Figure I'd document the journey on a build thread. I'll be backlisting some things to make it chronological. I'll try to fill it up with searchable titles, part numbers and picts to help those out, just like others have helped me.

I decided I wanted to get an M939, but the A2 version about 6 months ago. I had toyed with the notion of a multi fuel Deuce before, but decided against it. No place to put it. I live in suburbia in Colorado and have all the covenants that keep cool things like that on the side of the house / road. I have a very understanding wife and after some eccentric hobbies this one purchase seemed pretty normal as funny as that sounds. I joined Steel Soldiers after I found one on Craigslist and went to town on threads and then trying to understand the TM's. I just got the hang of it about a month ago. For those just joining, it's a daunting task, and you really need to get familiar with all of them just to see where to start. The Operator's manual is good enough to get familiar, but the Field Maintenance ones are really where it hits. The wording in all of those are really important, one little non emphasized word means a ton more to me know that I have got more book and wheel time. Just like most say, read, read and read. I still think it's cool that I can be a genius (again book) by the thorough documentation of the TM's.

This is my first military truck, and first diesel. I own a MINI Cooper. I also own a Galaxie 500, and now the M925A2. Tiny car, big car, giant truck.

Back to Craigslist. I asked the other half if I could go see the trucks with a friend. She knows what that means now. It means if I like it, I'm buying it. I went down south Colorado and saw the truck. Big, green, and cool. I felt a bit weird as, not having a diesel, felt a bit dumb, but that's why I had a buddy and someone who is on SS, and could teach me a thing or two. As these were pulled off the GL / GP lots, they were military good, with some serious dirt in the cabin, and surface rust. It had brand new XZL's on it, so it was a bit more than I wanted to spend. Plus I had my heart set on a Desert Tan one. I told him that, and he said, well, I've got one in the back. Took a ride in both and the tan one won me over, even though my buddy liked Big Green better. Nothing mechanically wrong with either, I just felt like Tan was home. So I did the walk away and think about it for the weekend, and compared notes with my buddy. I think he just preferred green..

Long story short. I committed, and was awaiting the Colorado title, which he had sent away for about a week prior. Three weeks later, after a business trip, I was all ready to get the beast. Nope. A grueling two months later it would finally arrive. One thing that might have gone against the seller was the time I had to read all sorts of threads on the machine. I learned all about CTIS, the engine, and the fun you people all have troubleshooting. I also found the GP auction where it came out of (easy to narrow it down, even before I was registered site user, Google and 925 and buyers from Colorado got me there in 2 seconds). The issues they had were the ones he was already working and disclosed. He fixed all of the issues that GP had listed, which was rust of the door plates, loose PTO, and a busted air dryer.

Here is a pict of the beast!

 

[therooster2001]

Changing the tire

In subsequent visits to the truck, I would learn a bit more and then get to check them out. He popped the roof a bit, it was caved in, and it came out great. It was stored in that tent for months so it was not getting wet,. We did later drive it in the rain, and the roof did leak, and I later bought a new to me top from Glenn at BFR. I had one last issue that I needed to get done before I took it though, which was a bit of a nagging thump. Could have been a flat spot on the tire, or a out of round issue that we solved by changing the tire. That was a **** of a job, but I am glad I have the experience doing it. I used the roboimpact, which totally rocked!

 

[AZK9]

Looks like a nice truck!
Good luck with your project!

 

[turnkey]

Now the fun will never end ...Get the Missy going on it also. You know like new seat covers...Pink or Navy Blue....things like that ...Never fails...My missy is in our MV up to her neck.....Getting to selected new seats...Airride..That she likes....

 

[Piper Cub]

Looks like a nice truck!

 

[therooster2001]

Visit to BFR and Recovery of an M934A2

Thanks! I did a recovery of an M934A2 with the seller in TX a couple of weeks ago. He got a drained one, and had it hauled to a truck place, and they were supposed to get all the fluids in. We flew in with a starter as they thought it had a bad one. Turns out starter was fine, but Black box or a miswire was causing some headache, as well as the fuel cut off solenoid, so we zipped tied the solenoid, and did the screwdriver across the terminals trick to get it moving. Cool vehicle, and I learned a ton of what to watch for when someone (a professional, or from the auction) tells you it should be fine. Ended up putting in 6 gal of coolant. And almost 4 gallons of transmission fluid (since it was drained he opted for the tractor hydraulic and transmission fluid), and fuel. Tough start, even the word "seized engine" came about early. That would have been a quick trip. Always check all the fluids yourself! Ran perfectly and we pulled into Glenn's place and started to pull parts for another 6 hours. Man is that tough work. I grabbed a new top, another spare tire, new cargo seats, bows, a new battery box, some small parts and lights, and bulbs. Glenn is a cool dude, I'll be making it back there. Pulled into Colorado after three days, then put all the parts in my truck. I highly recommend another one to carry parts! 10 minutes before the tire exchange for bed to bed, it started to hail on us.

 

[therooster2001]

Coolant Leak

Had to title and register it. Having a "fun" time with DMV at the moment. And missed the Colorado collector plates by a change in law. I had to get the emissions done (What?) for part of the process and went to a heavy duty truck shop. 3.5 Hrs later, they had it out. I got the opacity test and also asked them to check the torque on the front lugs that we changed. I did notice some fluid on the ground when they moved it. I say they moved it, but I had to go out and tell the mechanic how to disengage the parking brake. I know they don't drive these all the time, but I did note to ask me so they don't screw anything up. When I walked up to the truck when he was futzing around, I saw him trying the spring brake override lever. Ugh. The shop foreman did come out and told me that when it was on the Dyno they saw a coolant leak. I didn't trust him, so said no, button it up and let me have the truck. Drove it home without nothing but a known leak from the power steering reservoir that was a fit overfilled. The next weekend, I take it out for a short trip to fill up the fuel and come back and I see some coolant leaking. I pop the hood and find that my hose is now patched from a burn mark and zip tied. I checked the pictures from the auction and no zip tie. HMMM. Last time I'll take it there.

From the auction:


After the truck mechanic:

 

[therooster2001]

Venting Air through the stack

So I also ran into another problem that day. After finding the coolant leak, I back the big guy into it's garage, and because I'm a bit new, I'm on the brake more than I should. But with a normal backup, I drop the pressure fast. Too fast. Down to 40 on both tanks! Leak. I do note that it is venting out the stack. Yuck. Time to search. Couldn't reproduce it without Soldier B (or a brick), so the wife comes out and while she's on the brake, I run around trying to listen to the brakes. Nothing. I use shop air to air up the truck as indoors, it sucks to have diesel fumes.. Just used the rear emergency glad hand. http://www.steelsoldiers.com/showthread.php?26671-air-pressure-from-an-external-source Run it up past 90, then try it. After reading some posts and some other things to check.

http://www.steelsoldiers.com/showthread.php?126598-M923a2-air-question
http://www.steelsoldiers.com/showthread.php?116840-923a2-air-brakes-leak - Post #31

I think I found it too. The LQ-2. The video is quick, and a little uncoordinated, but I hear the rushing air, so think that's it. Went to the E site, and got one for $32 shipped.

Anyone know how to embed video inline?

 

[therooster2001]

Power steering cocktail

I had to get some of the power steering fluid out of the reservoir. It was coming out of the top of the filter. After a trip to Home Creepo and forgetting a syringe or a turkey baster, I run to the convenience store to get a straw, and do the finger over the end trick like 60 times, and bam. It's all done. Not recommended tool, but it did the job.

 

[therooster2001]

Well, today was not a great 'progress on the truck' day.

#1 - Not all LQ-2 parts are made alike. I took the advice (and warning) of a thread on here and ordered the EXACT part number. Well, it turns out that the outputs are 1/4" instead of 3/8". I know I could have reduced them, but it would have bugged me. So after no local stock at NAPA or a Truck parts place, back to the E site and ordered one. Hope it comes in before the 4th of July. Bought some deep sockets to help installing the pieces to the new one.

#2 - I bought an accelerator MWO kit from a member, the accelerator pedal is brutal. So I start the MWO, following the instructions and going pretty slow not to miss anything. I get about halfway through and check all of the parts on it by model number. Hmm. They all match. Lame. I think I actually have it installed already. The only part that seems to be different is the pedal bolt stopper. It's like 1/2 inch longer with a different thread depth. Does anyone know if this is only difference? It seems like a lot of effort to rip everything apart. I go through the instructions in my head and check the parts, so I just put it back together in like 5 minutes, where it took 45 to undo. Have a feeling that the MWO is on there and just needed a pedal bolt adjustment. I did find a spring that looked a bit worn. Added that to the list when I go see Glenn. Picture of the bolt difference. Everything else is matched exactly by part number (except the tiny cotter pins. No magnifying glass to check )



Bought some trucker chain from HF. $30 for a 20 ft 5/16 grade 70. Not bad. Also got some deep sockets to help with the Lq-2. Attached both of the "super" coupon. Just give them the code on the bottom. Expires on 6/30. Hurry

.

 

[therooster2001]

Figure I need to catch up on the posts.

The LQ-2 fixed the air issue as expected. It was a snap to put on. It was a maddening brake and then high RPM to get the air back, all while the low alarm was screaming away.

So, with the new valve on, I was able to put the car into a 4th of July car show in the home town (what ever happened to all the parades?). On the way home, luckily after I got off the highway, I was braking at a stop light and felt the back end slip out, and heard a terrible noise. Crap, it must be the ABS. I was in the wrong lane to just pull over, so took my left, then pulled over and braked again. There it was again. Here's what I found when I got out to look:

The torque rod end had blown the rubber out and detached. The next thought was, how do you get this fixed, and would I have to get an awfully expensive tow? Called the seller, who was taking me through the problem, and wife came to rescue me. The truck was receiving all sorts of attention. An old couple walked by and asked me if I was calling it in, and then the cops showed up. WTH? I got challenged on no plates (Colorado doesn't require them to be installed, just carried), and she was giving me the third degree about I had to get this off the road (a four lane road with no traffic, not impeding mind you) when another cop shows up and jumps out and say "hey, can I drive it?" The truck was drive able as the torque rods on the other side allowed it to straighten out, as long as I didn't brake. Braking caused the one tire to quickly stop and then because it wasn't held in place to twist the axle and mash the tire into the one behind it. Scary. Couldn't imagine if this had happened on the highway. So I limped it into a parking lot about 1/2 mile down the road with a police escort. Told them I could fix it, they were less than confident and told me I could still get towed from there. The plan was to align the rod and end and then pound it back on, and wrap something around it, then take it back 14 miles to home. Run to Lowes to get a sledge and a ratchet strap. Tried going back and forth, and then applying the brake which actually works to get the axle aligned again. Not fast, but backwards with a brake helps. I was about a 1/4 in off and think I could get it. Mistake. Had to be perfect. A jeep rock crawler stops and helps me out. We tried to winch it on, then move the axle. We just moved the jeep. After an hour, I reposition it by going back and brake, and we get it aligned. Winch it back on, then beat it on with a sledge. Ratchet strap it so it won't move, then a slower drive back home. Repair held, then to think about how to fix it, and do some reading.

 

[Piper Cub]

Glad you got it home ok! That's one part I always check before driving the truck, I never want to have to deal with a loose axle.

 

[therooster2001]

The next task was to remove and replace the torque rods. The TM says to remove tires, so I asked the smart peeps if this was really necessary. This thread captures the question, then the saga of removal, frustration, money and success.
http://www.steelsoldiers.com/showthread.php?t=141807

In the middle if that, we drove 6 hours to go see Glen and get some parts including the torque rods. Here's a picture of the lineup of trucks we got some things off of.

We had fun believe it or not, in the yard, and the Sunday we pulled in, it was 104. The wife came with me and pulled a bunch. She was really good at opening the tool boxes and finding all sorts of stuff. I found an air filter brand new in the bag in a front seat. Glen was awesome at accommodating us and gave me some great deals as usual. We came back with valves and rods, and even a metal bow we fit inside the MINI. An odd date, but we had fun in spite of the heat.

 

[therooster2001]

If you read till the end of the torque rod thread you see that the heater core was leaking on its way back from the heavy truck repair. The take apart was followed by this thread, post #9.
http://www.steelsoldiers.com/showthread.php?t=115488.
Easy, but a bit messy trying to get it out. I soaked the front in antifreeze. It was all over the floor. That was the longest part, cleanup. I took it to a radiator repair shop and we'll see how it goes after that. The radiator will probably take a couple of torques, and a missing nut to fix.

Changed oil and filters in the big guy in the middle of waiting. The oil was midnight black and the filter manufacture date said 08! Changed out the fuel filter too, but inspected and no rust or schmutz was found, so I think I'm good, but was good to get a filter baseline. Marked the dates on both filters to remind me.

Replaced a light housing that had corroded / rusted, and reattached a side light that some private had screwed up the installation on.

 

[Swamp Donkey]

Tried going back and forth, and then applying the brake which actually works to get the axle aligned again.

For future reference, chock the wheel you want to reposition in front and back. Move the truck forward or backward to reposition the axle. If you go to far one way, just go the other way. The differential will do its job where the tire with least resistance rolls and the chocked tire sits still, allowing you to slew the axle. Let the truck do the work for you.

I had to do this when one of mine let loose. The security feller in the Walmart parking lot wasn't amused, but what could he do....my flashlight was bigger than his, lol.

 

[therooster2001]

That's a really good idea. Why didn't I think of that?

 

[gimpyrobb]

When we had to line one up at haspin, we hooked a chain from the rear axle to the front tire, we could just spin the steering wheel to line it up. That only works if you have to pull it forward though.

 

[therooster2001]

Received a call from the radiator shop, he said it was all rotten inside and would be like $150 to recore it. Either I will go grab another one from Glen or try to try the Ford heater core as some have done.
http://www.steelsoldiers.com/showthread.php?t=115488. Bolted things back together to drive for now, it's 90 degrees and that's a problem for future Randy when it gets cold. Guess it gives me another excuse to go to KS.

What parts would you guys pull / have on hand from a parts truck to have spare just in case?

 

[JohnnyBM931A2]

Received a call from the radiator shop, he said it was all rotten inside and would be like $150 to recore it. Either I will go grab another one from Glen or try to try the Ford heater core as some have done.
http://www.steelsoldiers.com/showthread.php?t=115488. Bolted things back together to drive for now, it's 90 degrees and that's a problem for future Randy when it gets cold. Guess it gives me another excuse to go to KS.

What parts would you guys pull / have on hand from a parts truck to have spare just in case?

I would pull.... The whole truck Can't beat having an entire truck laying around with good parts on it

 

[therooster2001]

Probably going to see Glen this weekend. I have a couple of items on the want list, and probably will grab a full dash if I can find one so I can have a stock of gauges. Anybody have something that they wish they would have had as a spare that I should pull?