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On my 700R4 I have an Autometer "short" sender screwed into the pump pressure test port on the drivers side. Not sure how that would translate to a Turbo 400, but it seems to work well for me.

Some pics for ideas on how to deal with the Teflon seal...

FWIW I had the exact same problem you did with the timken kit. But I don’t recall the part number for the correct bushing anymore.

This is a horrible picture of a commercially available extractor tool. Try to copy this, taper it like the tool. Also, don't get too greedy when grinding it, you want to cool it often and not destroy the original heat treating. I would make the tip whatever size the drill was that you used...

That truetrac is a neat unit. Should be very street friendly since it is a torque biasing differential and not a locker. That is what I have in my daily driver pickup.

I have three friends that run around town in 73-87's that have a 6bt cummins swap. It is a great combo, does take some fabrication to get the crossmembers somewhere out of the way, cooling system up to snuff and the charge air cooler plumbed in. Fantastic torque, two of the guys I know are...

Curious what failed, looking forward to the the autopsy.

Yep, it is that easy. Worst part is smelling the gear oil. I remember driving around a Toyota 4Runner that had a manual transmission and a Detroit. It one one cantankerous thing to drive around town. I’m with you on the locker making itself much more apparent as soon as you add a manual...

I’d add in measuring backlash before you pull it apart, and match your as-found number when you put the carrier back in. It isn’t difficult, and I bet if you have some time on your hands you could get the guts out of a stock carrier for free or cheap from someone installing a Detroit.

Besides the whole crabwalking idea... have you checked how tight your front leaf mounting bolts are? If your front eye on the drivers side slips a tiny bit, or your axle slipped on the spring that could explain it. I’d retorque everything. You said that your draglink and tie rod ends are...

I have done a few steering boxes. Edelmann 8524 or Gates 350440. Rock Auto offers them for about $30 A few pointers... Read & follow the Saginaw 800 series service info here. https://www.midweststeering.com/service-information/ Keep things as clean as you can. Don’t rely solely on YouTube...

Wanted to follow up to this since it is 2019. The Viton hoses on the injectors are holding up well. No new failures. The only issue was that one that connected to the larger diameter crossover tube.

I'd pitch the stator in the trash and buy new ones. As for the rotor, maybe a light media blasting with walnut shells then a coat of glyptal paint? I'd be sure to check with a meter if the rotor winding is shorted to the rotor itself first.

I'd be hesitant to go with an alternator rated for that much current. As soon as that thing flashes the rotor after startup it would be belt squealing city trying to transmit a lot of horsepower on vee belts. You can get brand new bearings, brand new stator, brand new diodes, voltage regulator...

That is one impressive failure. If those bearings were that bad… and that dry, my guess is that the rest of it isn't in primo shape. Watch your local facebook trading post / Craigslist / Pick and Pull (self service wrecking yards). You should be able to get back on the road for a few hundred...

I know this is a bit like the Dr. Seuss Butter Battle Book where one side likes their toast with the butter side up and the other likes their toast butter side down... I have crimped somewhere over a hundred thousand Thomas & Betts brand terminals at work. While what the guy in the video seems...

I'd talk to the driveshaft shop you are using for measuring instructions. Also, there are extended slip setups available. The geometry gets pretty funky with that much lift, you can have such a difference in length from full droop to full compression that you may end up needing an extended...

If you decide to go with custom hoses read this quote from 85CUCVtom. The technique described is what I did. I had a set of "AC Delco" hoses last me less than 4 years before they started leaking, so I went with the method below, except that I used hydraulic hose instead.

Put new tires on the clone. The HMMWV Wrangler MT tires I had on it were old when I put them on 5 years ago, it was time for new rubber. Pitbull Rocker radials were on sale so I broke out the elbow grease and got busy dealing with 24 bolt HMMWV wheels... The tires are a little taller and...

Clean the daylights out of it and go crack hunting. Transfer case adaptors and transmission cases are known to crack.