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If you don't mind forking over a fat chunk of change I believe realdiesel.com has a rebuild service. Have heard good things, but the prices are steep.

I'm thinking of doing this swap too- came across some rebuilt HMMWV 6.2 engines in the crate through a guy I know. They look like they're brand new- shiny and clean, with capped openings, etc. So do I understand this correctly- to swap them you need to keep the CUCV: -intake manifold...

Check out this previous post on the subject: http://www.steelsoldiers.com/cucv/39904-injectors.html

Check all of your fuses. Replace the applicable ones- even if they don't look burnt out, for whatever reason, I've had this issue more than once. So far that's all it's been. If you want to hunt and peck with the multimeter there's probably a short in your accessory circuit somewhere.

Injector pump removal: (from memory, but check the TM. It covers it.) -Disconnect the batteries -Disconnect the IP solenoid (pink wire) -Remove the air cleaner -Remove the CDR valve assembly (valve, hoses and bracket) -Disconnect the vacuum pump lines from the pump modulator on the side of the...

Good to go. I'll check that first thing tomorrow. If I read the TM (Lube Order) correctly: If it's empty it should take 5.0 Qts full. Full would be at a level 4" below the fill hole. I've got an unopened gallon of Dex ATF in the back of the truck. Figuring I lost maybe a pint or a quart...

Well, it turns out it wasn't the tranny or the IP or anything else I'd surmised. Found at 70mph an hour from home and an hour from my holiday destination that it was the rear U-joint! Truck started shaking to the point I couldn't see the numbers on the speedo, and then it sounded like all...

Thanks. Do you remember the size of lines, lengths and fittings? Not sure this will solve my tranny problem, but it's a starting place. Something to maybe keep me on the road a bit longer. I've had problems that seemed like $100+ issues end up being a $.05 fuse or length of wire. Hoping...

BTW- where would I get new lines to run from the radiator to the transmission? Is it a specific part, pre-bent, or can I upgrade to flex lines, what type of fittings? Anyone with a quick answer? (I know I could research, and I will if no one knows off the top of their head, just throwing it out...

Okay, so I apparently do have a coolant leak I had somehow missed before. Went out today and the coolant had leaked on the driveway and was about a quart low (guesstimating). Seemed to be coming from around the bottom of the radiator on the driver side where the tranny coolant lines go in...

-It doesn't smell hot, but there's a bit of tranny fluid sort of condensed on the bottom of the pan. Doesn't seem to be leaking much though, as the level hasn't dropped. Not sure where the fluid is coming from though. Also, should the rear drive shaft be slightly slick looking at the back of...

Loss of power and shuddering- it was the U-joint! So after a week of lovely in-town driving, I took the M1009 out on the freeway and the evil shuddering came back. It does fine accelerating and shifting in town, and is good for about 15-20 minutes on the freeway, but after that it gets weird...

That's invaluable info, Chuck. Thanks!

Yeah- I guess that would be the distinction. To be perfectly honest, I've never come across a K5 civi diesel. Most of my buddies have gassers. So that would explain the difference. I always tell the O'Reilly and NAPA guys it's a K30 with a 208. Seems to work thus far. :D

Mangus- I was under the impression (read it somewhere, I'm sure) that the M1009 had a heavy duty suspension not found on the civi K5. And aren't the axles different, too? NMC- you just got bit by the Dog. :D ALWAYS indicate what you've checked in the TM and why it isn't good enough, or...

Well if it was that easy to fix the 6.5, keep it! *jealous*

Couple of Sanders/wire-brushes on a drill $15 2 cans of Rustoleum rust converting primer $15 2 cans of Krylon OD green $15 New upholstery job with fabric and foam from a craft store $30 Not paying over $100 shipping, and having the satisfaction of doing it yourself: PRICELESS *prices subject...

Couple of Sanders/wire-brushes on a drill $15 2 cans of Rustoleum rust converting primer $15 2 cans of Krylon OD green $15 New upholstery job with fabric and foam from a craft store $30 Not paying over $100 shipping, and having the satisfaction of doing it yourself: PRICELESS *prices subject...

If you have the know-how and the equipment to do it, I'd pull the 6.5 and put it in the one that currently has the 6.2. If you can't do that, I'd say keep the 6.2 as it has no problems and seems to be the better truck overall. If you're set on the 6.5 either try and fix the leak and trans...

I would almost always prefer to buy new or remanufactured stuff, but unfortunately I'm on a lean budget. What I tend to do is buy a local for temporary use- just to keep the truck on the road, and then save up for the new/reman part for the long term. It may seem more expensive, but hey, I...