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I'd start with the fuel filter. I'm sure its been awhile since its been done on that truck. I'm a fan of installing a spin on fuel filter with the hand primer like I showed you on my M1028. Another thing that comes to mind is the filter/sock on the sending unit in the fuel tank.

I wouldn't. For the cost of a gasket & some oil why take a chance?

What brand oil pan did you buy? Did you find a higher quality one?

What was the cost to have the transmission & transfer case rebuilt?

Off Road Design (ORD) has the stud kit for the Dana 60.

5 pages deep and not 1 comment on how to maintain or repair a CUCV.

Any updates?

I've had good luck cutting the bolt off with a sawzall. I put the blade between the eye of the spring and the spring mount on the truck frame and cut away. On rusty New England trucks even if you get the nut off, the bolt is usually rusted to the metal bushing sleeve. Good luck

I'm looking forward to pictures of the projects that you have lined up for the summer of 2016.

Welcome from Mass. I just seen this post today. I'm glad you got the truck back on the road and are driving it. Your getting some good mpg's out of it. You seem like you dive into your projects head first and get them done quickly. I look forward to watching the progress of my old truck.

Didn't that truck have 31" tires on it when I sold it to you? I recently sold a set of M1009 rims for $250.

I'd bet you could buy a nice CUCV for what it will cost to fix the 2015 Sierra. It sounds like a few rebuilt driveshafts and the fleet of CUCV'S will be back up & running. Got to love the tuff old trucks.

Where in Mass is the truck?. If your on the South Shore I can bring you tools or a spare battery to limp it home on.

It's not that I need the K20 to be 24 volts, I'm thinking it would just make for a cleaner install using factory wiring. If I keep the k20 harness I will have to splice in wiring for the temp sensor, oil pressure, fast idle & fuel shut off. Maybe I should start looking for a 6.2 12 volt...

I bought my first CUCV back in 2009, right around the same time I blew up the motor in my Civy k20. I have owned 17 CUCV's since then, while the k20 has sat inside untouched (with a blown motor). I currently own 8 CUCV's (a clean M1028 and M1009) the rest are typical rusty New England parts...

Glad to hear that your up & running.

I just had an original 24V direct drive starter rebuilt at a local starter/alternator shop for $165.

I had the same problem with my 84 M1028. I tore my column apart and I quickly realized I was in over my head. My truck was an early 84 and didn't have the set screw for the ignition lock which added to my problems. I then did a search on S.S. and found some old post covering this topic...

Cucvrus has changed them over to 12v. I'm sure he can walk you through the process.

I'm with Cucvrus, I think its time to get your starter rebuilt. I just had a 27MT starter rebuilt at a local starter/alternator shop for $160.