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Back to its Marine roots! Installed the DWFK after previous owners had removed most of the components.

I pulled and tested all of my plugs just to either confirm or eliminate them during my S3 box troubleshooting. I put my probes on the connector nipple and the outer casing and they all metered at between 2.0 and 2.5 ohms.

My assumption would be Dextron III is already in the tranny since it replaced Dextron II in MV's many years ago. From what I know both are compatable anyway. For what it's worth, I switched over to synthetic when I got my truck a few years ago. Good stuff but much more expensive. It also...

Curious question: if I were to disconnect the gen and starter and reconnect them one at a time to isolate them from the system to troubleshoot if one of them is indeed the source of the power draw and S3 clunking, would this work? Or is the system all tied together to the point where they're...

I've seen on other posts both in here and on the G about how the 60A gens have been blamed for killing the batteries with power off. I'm still educating myself on humvee electrics, so with all things being equal if my 60A is the culprit is it conceivable that the issues with the S3 box are a...

When the first S3 box I installed died I replaced it and took the opportunity to replace the starter while I was at it. At that point I also discovered the engine harness was all corroded and needed replacing as well. On the truck's first post maint test run the gen overheated so I replaced it...

Yes, new engine harness has been installed because the old one was age cracked and corroding. New gp's that all metered fine, and both starter and gen are new as well. The 60A gen is a rebuild from TNJ and the starter is what I suspect is a Chinese clone from Woolfer. I wouldn't mind upgrading...

I metered the gen and it's still putting out 28.5 V. Unfortunately the S3 sh*t the bed once again and drained the batteries again over night. Something is intermittently clunking the S3 and draining the batteries and I'm wondering at this point if the gen is responsible. I pulled, cleaned, and...

Welcome from Ontario, Canada! My only advice is the humvee is an awesome vehicle on multiple levels and commands attention (both good and bad) everywhere it goes, so be very cognizant of that. As well, you will never stop throwing money at it, so deep pockets and a tolerant spouse are a must.

After doing some maintenance on the cables going to my 60A I discovered the terminal protective cover was inadvertently making contact through a break in the pos eyelet plastic shielding. This caused the gen to whine and get hot. I realized something was amiss after about 5 or 10 seconds of...

I'm on my 3rd S3 box now in less than a year. One goes through the wait cycle but no start. The other won't cycle and draws battery power even with the switch off, and has the audible clunk when the neg battery cable is unconnected/connected. The newest box worked fine at first but started...

I've got an S3 box that does everything it's supposed to except start the truck. The same issue on another thread (either here or in the G, can't remember) the owner dissected the box and found a stuck relay to be the culprit. The easy fix is to replace the box. If you know an electronics SME...

I had one that was in there super tight as well. The previous owner must not have wanted to tackle the issue because he was nice enough to paint over the plug and call it a day. The one method that i thought would work beyond a doubt was soaking it on both sides with penetrant for a couple of...

My S3 box was continuing to draw power when the switch was off. I suspect a stuck relay inside. The way I learned the box was the culprit was when I reconnected the battery cables after re-charging and I heard the audible clink of the box as soon as the negative terminal made contact with the...

I'm on my 3rd S3 box in as many years. They just suddenly die for no apparent reason, even when you've covered all of the bases to prevent it. Unfortunately they're a common fail item that isn't cheap to replace because Uncle Sam has deep pockets. The only way around forking out the big coin is...

I also had an issue with fluctuating voltage readings, in my case at the engine harness cannon plug to the S3 connector. In spite of external appearances, corrosion inside the cannon plug itself was the culprit.

No start as in you turn the run/start switch and nothing happens? Or merely turns over on cold cylinders without starting before the battery dies?

The best thing to do is pull apart all of the connections and grounds, and clean & inspect them thoroughly. Look for corrosion, damaged, clipped, and repaired wires and connectors. Take nothing for granted and assume nothing on these vehicles. Refer to the diagrams in TM 9-2320-280-20-2 Unit...

In the battery compt there should be a large POS cable going from the fwd stud that passes through the bulkhead going to the POS stud on the fwd battery. The big NEG cable comes from the shunt to the NEG stud on the aft battery. There's a cable connecting the two batteries together on the other...

I use dialectric grease on all of my plug connections. The big thing with the S3 box cannon plugs is to make sure the one in the engine compt has a good coating on top where the wires pass through the rubber. The plug sits vertically, and if there's any age cracking in the rubber seal at all...