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I got the 6.5 heat shield, will try to fit that up this weekend. I think that will help a lot. The latest issue is apparently the SM465 slave cylinder interferes with the driver side exhaust manifold. Has anyone ever had a manual in one of these trucks with a 6.5 turbo? If so what did you do...

Ok, a short update with a couple more questions and photos With the short injectors installed and a tiny bit of bending on the starter heatshield, the turbo manifold seems to install without any interference. I don't have the injector hard lines on yet but I think they will clear no problem...

Plus the M1009 already has huge 24v cables going to the distribution panel by the bench seat, so it would only require adding a single 12v wire. This is what I'm planning if I can't fit them under the hood, but was just wondering if anyone has done it already

The driver side is kind of a disaster, with an ac compressor and 2 air compressors. Not much space over there. The batteries need to be on the passenger side, or back under the bed floor/in the cab probably

Thanks. I'll take a look at group 65 batteries if I can't get my 31s to fit. They're less than 60% of the weight which should definitely help with the fender breaking. They have about half the capacity of the group 31 though, so I'll probably need to add another battery for my refrigerator...

So, I got the 6.2 manifolds off over the weekend. It took an average of 30 min per manifold bolt, but I didn't break any of them in the block. So that was nice. I ended up pulling glow plugs, injectors, and moving all the engine wiring out of the way and made space to use the acetylene torch. It...

Thinking about this a little more, is there any advantage to replacing a head gasket which is not leaking? I don't want to use studs, so I would be reinstalling with a new set of factory style torque to yield bolts. I'm worried if I take the heads off and the head and/or block surface is not...

Do you need to take the hood off to lift the heads out? They look pretty heavy (60-80 lbs?) and I'm not sure how to set them back on without disturbing the hee head gaskwt

Does anyone have advice for removing stuck exhaust manifold bolts? I've been spraying them with PB Blaster every day for a couple weeks, but when I tried to remove them this weekend they were still stuck pretty tight. I usually just go straight to an oxy acetylene torch and get everything nice...

Does anyone have a good source for sheet metal for these trucks? My front inner fenders are a bit rusty, and the passenger side is cracked where the battery tray mounts. I definitely want to replace the passenger side, and am trying to decide if there's any difference in fit or quality between...

Yeah I agree, its too low for this setup. I am in K5 on 33" tires, 3.73 axle gears, and a SM465 manual trans with Advanced Adapters "Ranger" overdrive. Cruise RPM is 1900 at 70 mph. I'm hoping for 18+ mpg with that setup, but we'll see what I can get. No smoke visible in the daytime, and just...

I got a bunch of 6.5 parts several years ago, and am finally getting around to installing them on my 1009. I have some questions about assessing engine condition and I am sure I will have more questions as I work through the swap, and will document everything here in the hopes it helps someone...

My 1009 has been a daily driver for 5+ years, and the engine runs fine. Never had any shavings in the oil at oil changes, no knocking while running, or any other evidence of extreme wear. The "Low Oil Pressure" warning light comes on with the key, and goes out immediately after starting the...

I am getting ready to do a 6.5 turbo swap into my M1009 and am starting to collect parts, and have several questions. I've seen Diesel Care in Memphis recommended by Cucvsrus and others on here, and their IP rebuilds seem to run between $450 and $750 depending on what you buy. They don't...

what twin stick shifter are you using? Any pics of the shifter or linkage? when you say "slipping" you mean its just coming out of gear into neutral? A gear drive transfer case can't "slip" like an automatic transmission (obviously). Its either in gear, or its not. How do you limp it home...

Do you remember the part number of the thermostat you used? I've had the same problem for a long time and have tried several different thermostats with no success.

The dash gauge is mechanical, and it agrees +/- 1 psi with another mechanical gauge. The other one is fairly cheap, probably harbor freight, but either both gauges are right or they're both wrong in exactly the same way. Definitely a good suggestion though, and one of the first things I did...

I have a 6.2L in my 1009 that is running, but has low oil pressure (25psi cold idle/45psi cold at 2500 rpm, 5-ish psi hot idle 30 psi hot at 2000 RPM), what seems to be a slow oil leak from the rear main, low power, and just seems generally tired. I've been running the truck like this for going...

Just to clarify, I would not suggest using an SM465 without an overdrive/splitter and with 3.73 gears. Like the original TH400, the 1:1 4th gear is not enough for highway driving with the current speed limits and engine RPMs will be too high. If you do install an SM465, I would suggest keeping...

I have used NAPA Gold 6096 for my 1009 for years, but recently finished off my last case of them. I'm shopping for some new ones, and there are several options I was hoping to get opinions on. Napa 6096 - probably the best, $21/ea + shipping https://www.fleetfilter.com/filter/46096.html Delco...