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Hmm... I'll have to look again tomorrow when it's light out, but it appears that my truck has a NP205 T-case. The picture in the LO looks exactly like what I saw when I was out there today. The plugs I pulled were pretty obviously the drain and fill plugs.

Sorry, a M1009. I will look at the LO again.

So, I went out today to do two things: 1) Doghead Starter Relay mod. SUCCESS! Thanks Doghead! 2) Continue with my one-step-at-a-time Lubrication Order. Today I was going to change the Transfer Case fluid. Here's where the problem happened. I pulled the drain plug out (lower-most square...

I have wondered about that place on Western just north of Belmont. I feel like an expert diesel mechanic driving my M1009 around for 10 minutes could probably save me a heck of a lot of time trying to figure this stuff out on my own. I'll probably re-pack my front wheel bearings in the next...

I am experiencing a sound something like a BB rattling around in a clothes dryer. Could this be the flex plate? Is this a problem urgent enough to stop driving altogether?

nope, mine's a sanded-down green CARC (previous owner had a lot of weird ideas, like painting the seats with vinyl paint that's now all flaking off). I'm at Spaulding and Beach (headquarters of the Latin Kings I'm told). Anyway, YES! Let's get together and get these things fixed up! I took...

@chicagodiesel: where are you located? I'm in Humboldt Park.

Great ideas, thanks everybody. I have changed the engine oil / filter about a month ago. Have all the stuff to do Tranny, T-Case, and Front Diff. It's got a brand new rear axle assembly in it... see other threads for that debacle. I put in a new (Onio Generator) starter and I bought the...

My M1009 has been doing pretty well lately, but sometimes it runs with that sound as though something is slightly off-center. Not the full-on "beater" sound, but a rhythmic "wum-wum-wum-wum-wum", especially evident when accelerating and at lower engine speeds. At faster speeds it may just be...

I had another thought (it was raining in Chicago today, so I was using the wipers). It may be a spotty electrical connection somewhere in the circuit. Maybe try cleaning the contacts wherever they can be found?

Mine act all kinds of strange, too. Usually they work fine, but sometimes they won't come on at all or they'll go reeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaaaaaaaaaaaaaaaaaaaaaaaaaalllllllllllllllllllllllllllllllllllllllllllllllllllyyyyyyyyyyyyyyyyyyyyyyyyyyyy slow (like a 60 second trip from "down"...

Try Ohio Generator. The guy there, Tom, build replacement starters for the military back in the late 80's and 90's. He'll build you a replacement starter for more than China but not by much. Mine was $199 shipped. He has some opinions about why they burn up so much, which I can't remember in...

I don't recall what type it is. Custm86 do you know? I believe it is the original type with only a few modifications to improve longevity. I remember seeing a military document stating that the Ohio Generator type can be rebuilt using parts from the stock one and vice versa, with only a few...

Something else I read (and that Tom told me), is that the "wait" light goes off too soon in these vehicles, and that if I wait another 5-10 seconds *after* the wait light goes out, the truck will start right up. I've found that to be completely true, which will surely extend the life of my...

Mine from Ohio Generator is still doing great. I bought the relay for the Doghead mod and I need to do that asap...

In other, possibly-related news, the truck is experiencing a "shudder" when accelerating. Felt mostly in 2nd and 3rd gear in the higher-half of the rpm range. It seems to be a function of engine load. I'm worried that this is related...

great... I am having this same problem. anything I can do to diagnose/fix this before it cracks my t-case?

OK, so I went in this morning and they put it up on a lift (wheel lift, unfortunately, so we could not operate the diff while watching it). Opened it up and got more of that sewer smell. I've been trying to put miles on the truck before taking it in and have driven maybe 50-70 miles, about...

We should. I've seen a couple other M1009's around the city. It'd be good to meet the local enthusiasts and maybe help each other out with parts, repairs, etc.

I got Ohio Generator to build me a new starter and I love it. Apparently he (Tom) supplied the military with replacement starters back in the day. He claims to have redesigned it to be a lot beefier, and it sure as **** sounds that way. Mine was $199 and that included shipping. I've only had...