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New relay here as well after the bypass. All is well for 6 months now since.

Speedometer Cable and Tail Lights M1009 - Found and fixed an annoying rattle that would only show up when stopped in gear:doghead:. Been living with it for months. It was a doozie to diagnose. Sounded loud and clear in the cabin. Chocked the wheels, locked the e-brake and poked around all...

Test your brake fluid type! Yes, absolutely you need to make certain not to mix the two different types (DOT3/4 with DOT5). The military specified DOT5 for these trucks, and converted all of their vehicles over to DOT5 starting mid 1981 (see attached). Simple to test. Get some DOT3 brake...

Should be a ground on the passenger side frame rail in front of the front battery. Also, the ground strap at the back of the engine on the passenger side.

I've yet to run into an impossibly swollen plug that couldn't be removed from the GP port. But, contemplating ways to resolve this I've wondered whether or not a shop vac hose held up against he injector port would work as well. Anyone ever try this?

What do they treat the roads with across "the pond"?

I suggest replacing the hose clamps while you are at it. Cheap insurance.

My pleasure. They are cheap enough that I keep one in the glove box of each of my manually tensioned vehicles, as well as the tool box in the shop. I also keep spare belts. That way I can replace a belt properly if one brakes when on the road. Full Disclosure: FWIW. I am in no way...

You are the one that bought that truck! Cool. I saw it online for quite a while. I liked the VFW connection. Best of luck with the project.

Belt Tension Gauge Check this out: http://youtu.be/z11wfc-0-hY About $10 - $12 and works well.

Thanks for the info. By chance, did you use a belt tension gauge to determine the actual tension on these belts? Tension spec. is 67 lbs. for a belt that has been run in for 15 minutes at much higher tension (approx. 146 lbs.). Check the -20 for the procedure. I'd be interested if these were...

If only on-road diesel was $4 around here. You are fortunate my friend. Drive her and enjoy!

There is a drain hole at the back of the valley that allows liquids to drain out through a tube that exits the side of the engine block. If there was a critter spending quality time in there, I'll bet that they plugged that hole. Something you might want to check.

Battery Charging Recommendation Congratulations on getting it running! As a general rule, throw a full charge into any lead acid battery before first use. Not always possible, as batteries sometimes quit at the WORST POSSIBLE TIME (of course) aua. But if you can manage this, you will...

1) The thin white covers cover up the 24 volt bus. The battery tender is a battery charger that is also supposed to de-sulfate the batteries. 2) The Optima Blue Tops have additional terminals. Looks like the PO utilized them to wire something. 3) Could use some tidying up. See #1 4) Web...

And, is that an M101 attached to the M1008?

Outstanding! Thank you for sharing. And godspeed to any who might be in harms way!

Congratulations on the beginning of your addiction to green iron. Looking forward to the pics.

Troubleshooting Using the TM's I believe there is a section of the troubleshooting procedures that deals with your symptoms. From the -20 Technical Manual TM9-2320-289-20.pdf "USING YOUR MANUAL: AN EXAMPLE The operator of a CUCV truck complains that the truck engine cranks but will not start...

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