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Been driving my 85 M1009 ("The General") for three years, and now its time for General V2.0! It's getting a set of 3/4ton axles, 2" add-a-leafs and Zero-rate blocks, 35X15 Swamper TSL-SX tires, and the turbo setup from a '93 K3500 6.5TD. Heres some pix from the first stage, swapping in the GM...

Used to be, my M1009 would start right up after it had been warmed up, without using the glowplugs (fortunately I've got them on a button). Recently though, it began to need a few seconds of glowplugs even if I'd just shut it off. And now it's getting worse, takes about 10sec of glowplugs even...

I did the conversion, which worked fine, but later removed it in favor of two hi-amperage momentary pushbuttons on the lower dashboard -- one for manual glowplugs and the other taking the place of the starter relay. To start the truck I switch the key to the run position, then hit the buttons...

If you're taking the heads off it would be a good time to replace the water pump. It's only a $50 part but a real pain to reach it with the engine completely assembled

I've got a ZeroStart block heater from NAPA, it was about $30 and works great here in upstate NY. Plug in for about two hours even in sub-zero and starts right up. I installed it in the middle freeze plug of the drivers side, and the cord is the perfect length to run out the grill behind the...

As for the stock wiring, I just rolled mine up and zip-tied it out of the way behind the vacuum pump. I wonder if I'll miss that fuel heater come winter; might have to make a coolant-fired heater inflow with the heater core, so that when it's cold enough for cab heat it heats the fuel filter...

I've used the Walbro FRB-22 (marine version of the FRB-5). It worked well for a while, but started sucking air between the housing and the lower fuel bowl, causing me alot of grief, since I checked everything else before suspecting my brand new $120 fuel pump. I got it from the walbro website. I...

SUCCESS!!! And a valuable lesson for anyone installing an electric fuel pump... First, I tried Stampy's idea of pressurizing the fuel system to look for leaks. That was a good idea, although I found it necessary to seal off the return line with a bolt and hoseclamp in order to build pressure...

Thanx for the suggestions, but... The valve is on the OUTLET side of the filter unit, on a T with the supply to the engine. That's why it is closed, it is for bleeding air or transfer of fuel. Air is accumulating INSIDE the filter bowl, ahead of this valve, meaning it is coming from the supply...

Just installed this Goldenrod filter system. The gauge on the left tells the pressure from between the electric fuel pump and the filter, and the petcock on top is for bleeding or transfer of fuel. The element is a 10 micron water-block. When I put this together, the truck would run for about...

you could always adjust the steering-stop on the left steering knuckle so it wouldn't turn that far...

I'd say after it's all hooked up, crack the seal on the return line to the tranny and crank the engine (with pink wire removed) until fluid seeps out. Then replace the wire, start the engine, check the fluid level running, and top off if necessary. This will prevent a "dry-start" for your tranny.

I installed an aftermarket tranny cooler, trans temp gauge and trans pressure idiot light (lets me know if I just ripped out a trans cooler line on a tree stump). Cant get any pics since its all buried behind the front grill now. I mounted the cooler with L brackets to the sheetmetal in front of...

Checkout RockAuto.com, I got one there for about $275 including shipping to NY. Look for the one with the most plates in the oil coolers.

Thanx for the pic, Southdave. The two holes on the side of the transfer case are for a torque rod that goes from the TC to one of the bellhousing bolts on the tranny. Most CUCVs seem not to come with it, while most civvy trucks do. Weird. I made my own, since I've broken a cast-iron transfer...

Since the untimely failure of my Walbro FRB-22 electric fuel pump (after only 1yr), I've installed a Holley "Blue" electric pump instead, because I had it lying around. It's 110GPH, 14PSI, which should be OK, but it was made for gasoline. The Holley website says not to use it with alcohol...

I was thinking of buying the swaybar disconnect to install along with my with my front zero-rate/2" add-a-leaf setup. How did the swaybar disc. work out for you?

So I finally tracked down the air in my fuel system to the almost new (1yr old) walbro frb-22 electric fuel pump (marine version of the frb-5). This was literally the last place I looked. To test it i've got hosebarbs on the inlet and outlet, fuel hose running from both (with hoseclamps) into...

If the fuel cap is not vented, and the tank is not vented, how does the pressure equalize as fuel is consumed?

I just installed an Autometer diesel tach on my M1009. I found one on Ebay brand new for $80. It was easy to install, I put it on the steering column using a long hose clamp, and the probe goes on either alternator using another long hoseclamp. Works great.