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As Cucvrus said, I would add though that the Cucv passenger liner has 3 reinforcements that are spot welded, I drilled out the welds and welded them in the new one. That is optional unless you plan to use 6tmf batteries or are a stickler for keeping it original. I got my liner from Jc Whitney...

Thank you, that was exactly the kind of info I was looking for. Of course, I was looking for an easier way like a restrictor between the pump and steering box, but that isn't always what we get is it. Thank you!

I have the Kevlar Goodyear tires with a very aggressive tread, they are at 45psi, the tires are marked as a 50 psi but I went with what I have seen as the most common inflation pressure for an M1009.

Is there any way to increase how much effort is needed to turn the steering wheel? I am not talking about slop or play, the steering is "tight" in that regard as the box was replaced with a rebuild, all joints and linkages replaced, the dampner is new, the steering shaft is now a universal...

Fwiw, having replaced my multifunction switch and fuel sender, their is no other interaction of these components except at the cluster. They don't have any other common connections.

I would be inclined to agree with doghead. I had a similar issue, switching the turn signal caused a hazard light type display and a gas gauge dance. When I reconnected the plug to the dash one of the leads on the board folded and came in contact with another. My board was in good shape except...

I would be inclined to agree on the mechanic. All this is is a gm square body, over a million made and anyone over 50 with mechanical knowledge should be familiar. Most police cars have a comparable black out system so a decent mechanic should know that too

My guess on your gauge/ turn signal issue, someone removed the dash cluster in the past and the plastic sheet that has the "circuitry" has peeled so the contacts for the plug are overlapping, when you switch one thing, power crosses over to something else. I had this problem myself and it seems...

I would keep it stock, personally, it was the 24v system that sold me on the Cucv. Search eBay for 24v mil surp tools or truck driver appliances and you will see all the functionality it adds. It is a very simple system, I think people over complicate it rather than just following the wires and...

There is no conversion, everything 12v just use the front battery only, 24v uses both. Lighting suggests a problem in the blackout circuit, key issue suggests the ignition switch which the key actuates has moved or was replaced by a wrong one.

I have one hunch I am going to try, that little group of 3 capacitors on the fire wall between the hot and ground. I am kind of stickler for keeping things right and at least reversible so I made a new one myself from the proper capacitors. I am going to try removing it. I can say that this...

Also, keep in mind that the gen lights and heater circuit are part of the charging, if the bulbs are missing, burned out or heater blower doesn't work, check that first.

Get the charging issue resolved so you don't have to learn a lesson the hard way like I did. If your voltage gets low, the starter solenoid will weld the contacts and run on, you will then be in for a rough weekend of rebuilding a starter, two alts and replacing fusible links and two bats, it...

Since it turns over I would lean toward fuel delivery or glow plugs. Does the Wait light on the dash come on during preglow? Do you see a dip in the voltmeter voltage during the preglow cycle? If not, the card or relay could be faulty as could the wiring. Also, a lot of the glowplugs tend to...

I was surprised by the fact the copper/brass are no longer available. I bought a spectra 4 core copper about 18 months ago. As far as the oil cooler lines. They mushroom out and won't reinsert in the new radiator. Patiently sand them down until they just fit. I got impatient on one and I have to...

I should clarify this is an m1009. The speed is plausible I suppose as it would be rpm related but on this particular drive I had a full mix of county and farm to market roads with 55 mph speed limits and a short highway run at 75 and I had about 2 miles off road. The gen lights do seem to be...

Searching this topic I find a few threads, but none post a resolution. alts were both rebuilt with asp wholesale kits and hardware kits after my starter/wiring meltdown I have another thread about. Fusible links and all main cables were replaced, fuse block, grounds, terminal blocks were all...

You are right one long azz belt with no extra pulley, crank to compressor. When the compressor is on it slaps and that is why your motor mounts better be optimal. I am not knocking the kit or the company, it works and I am happy to have it. Retrofitting a 30 year old vehicle is expected to be...

This is interesting, with the nostalgic kit the compressor is to the right of the 2nd alt. My nightmare has been working in a cold air intake. I had assumed turbo was right out but maybe it isn't, but cold air intake is still a challenge, I got a silencer off a civy model and it makes a world of...

I will second that on the instructions, vague and with horribly blurry black and white photos. More or less expect a box of parts and have fun. I did find they were helpful by email with any questions. You also brought up some good points. My evaporator was freezing up and I was told to just...