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Well went ahead and replaced the calipers tonight. And good thing I did, this crap came out of the old ones however it's still pulling to the left, and I was getting a lot of air bubbles from the left side. I'm going to try and rebleed it and tomorrow.

I don't think it's likely the flex lines? They're only a year and a half old. I was thinking that it may not be the drivers side caliper not retracting, but the passenger side not extending? I'll steal some time tomorrow, pull the passenger caliper and see if I can make it extend.

Well.... A new problem has reared its ugly head. I just got back from a 100 mile trip and the drivers side caliper is holding pressure. I pulled it all apart AGAIN! And with the caliper off and sitting on top of the axle. I pumped the brakes and the piston moves out. I used a compressor to push...

*Edit* Banks instructions call for a 1/4 turn.. My bad

I just walked in the house from doing just this LOL!! There was some (slightly) rusted spots but I cleaned them up with a wire brush and a piece of sand paper. Re-lubed everything and put it back together. The only other thing I could think of was maybe I was installing the little, jamb nut...

So I guess my question boils down to this. Is there a different type of grease or lube I should try? Perhaps just anti seize?

When you installed the turbo, did you turn up the fuel? And if so how much? With the banks sidewinder I installed on mine the instructions called for the fuel to be turned up 1/8 of a turn. I typically tow around 3000LBS down the highway at 70-80MPH. M1028, Banks turbo, 4.56 gears, 31" tires...

No mud, this truck lives on the highway. I got 30000 miles out of this first set of pads. So I figure if I can get the calipers to function properly I should get at least a third more life out of this next set?

Sorry it's a M1028 so I guess that means it's a Dana 60? It doesn't have the pins the calipers just slide on a groove. this is the lube I used originally & just now.

So I just changed my front brake pads. And both outer pads were worn, but the inside or piston side pads are barely worn? Also sense installing the new pads, the truck stops significantly better. The calipers & pads were the first things I replaced when I bought the truck 30000 miles ago.

I replaced my passenger side inner fender a little over a year ago do to battery acid rotting it out. The original braces were rotted and unsaveable. I was in a hurry and just installed the fender as is, with no braces and have had no problems:shrugs:. That being said I used optima batteries...

In regards to your HMMWV tires, I had a similar experience but with the old stock 31" tall Goodyear tires when I first got my truck. Sometimes they'd run fine, then other times wobble like ****! It turned out to be the tires dry rotting from the inside. I went to get them balanced and my tire...

Agree

Installed a new service light and mounted the switch between the blackout switches..

Yeah my M1028 gets the identical MPG loaded as it does unloaded (13.84):shrugs:. Which leads me to believe that MPG is RPM, not load related. I'm hoping 33" tall tires will be an improvement.

I know we're talking M1009's here but I thought I'd list my numbers incase it helps... M1028,.. Banks turbo,.. Gear vendors over drive,.. stock 31" tires,.. stock 4.56 gears,.. Best so far 13.84MPG- highway 70-80 MPH... I found by eliminating the Banks muffler and installing a glass pack gave me...

I drive my M1028 about 3000 miles per month, mostly highway driving. What works for me is to close the passenger windows, then open the drivers window & vent, and both of the foot well vents. Then I got one of those Walmart clip on fans and clipped it to the passenger rifle mount. I think it...

Agree, just cut the bump stops off. Do to the overload springs they're pointless anyway.

I would put a temporary piece of clear hose in place of the I.P. return line. This will show if your getting air into the system.

If you could pull it while it was hot it would probably work. Otherwise you could rotate the piston to TDC and break off the glow plug. Then remove the injector and pull the piece out from there.