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That's a great idea! I'll definitely be doing that as well as picking up some carbide bits. I already broke one today, and that's when I decided to call it for the day. I spent all day the previous day getting my motorsickle back on the road so the broken bits were a good excuse to give myself a...

I think I found one for the direct drive starter, I'll try it out and if it doesn't fit I'll send you a PM. I appreciate the support!

Well, my bolt seems to have broken off very cleanly. I couldn't find even the smallest should to grab onto, and it's deep up in the block. Looks like I'll be using a bolt extractor. Also, does anyone know the pn for the front bolt bracket? My starter is missing it, which is probably a big part...

Ahh, got it. Thanks guys! I should be taking off the starter today so I can take a look at the broken off section and hopefully I'll have a little bit that I can snag to turn it out instead of having to use a bolt extractor.

How do you use the ice pick to get a broken off starter bolt out? And are you just referring to a standard ice pick (long, slender, pointy piece of metal)? Or is there some tool called an ice pick that I'm not aware of.

Thanks folks! Looks like I'll go with the rebuild of the current unit. I haven't taken it off the truck yet, so I've still got some time to figure out where to go but I'll call stanadyne as suggested. If anyone else has recommendations for rebuilds in/around San Diego I'm all ears, and thanks again!

Hi, I have a 1986 M1009 that needs a new IP. Where would you guys recommend going to buy the replacement? I've heard lots of stories about guys buying replacement pumps which turned out to be total crap and failed on them again shortly after the install. If anyone knows where a good source is...

Well I know this is a very old thread, but I stumbled across some pictures from the trip yesterday and thought I'd report back. The batteries had no problem starting the truck, despite the very cold temperatures and snowfall on the trip. The rear U-joint on the other hand, didn't fare as well...

Should I be switching my service lights off on my M1009 whenever I park it for more than 24 hours? I always just leave mine in the all on position, haven't had a problem so far...

I rebuilt the transmission! I suspect mine had the seal between transmission and transfer case go bad (a bad seal on a 31 year old truck?? Unbelievable!) since the transmission fluid had seemingly disappeared with no traces of an external leak. Every time I walk up to the CUCV I look at the...

Are your resistors fully operational? When I first got my 1009 I installed all new GP's, replaced the relay and did the card bypass with a momentary on switch, I poked around with a multimeter and thought everything was good to go yet she just wouldn't start unless it was really warm and sunny...

This was the first winter with my m1009 and with all the leaking into the cab from the fender vents and rear shell, I just knew I was going to have some floor rot under the rubber mat. I pulled it up, and used an angle grinder to remove the coating from the floor. I was pleasantly surprised to...

So did anyone ever figure out the correct Bilstein pn's to use on a stock height M1009?

Does anyone know where I could find one of those mounts for the inside cargo area? My 1009 didn't have it in there when I bought it.

Thanks for the input on a difficult theoretical question! She does crank over quite nicely in San Diego, ****, most days here I don't even have to use my momentary glow plug switch to get her started. I did a full inspection on her and my plan now is to just drive and if I get stuck I'm sure...

When I bought my m1009 a little over a month ago, it came complete with two fresh batteries dated 08/16. Living in San Diego they have never stumbled in providing adequate cranking power and so I've never ventured to look at the cca rating. However, within the next few days I will be driving up...

I actually misplaced my crimper a while ago and have been using pliers hoping that the crimper would turn back up, but it looks like I need to bite the bullet and buy another set. I haven't had problems using my crimpers in the past, but apparently my crimping skills with pliers aren't very...

Thanks for your help guys. I pulled down the doghead relay to test it and that's when I realized that the purple and white wire wasn't connected. Apparently I had done a less than good job of crimping that wire into its ring terminal when I did the mod and it must have popped out on the trail...

Hmmm, I actually did the doghead relay mod already and had been running it for quite some time with no problems. The trails today were pretty rough, I wonder if all the bouncing around did something to the relay? Even after I installed the doghead relay I never heard a noticeable click from it...

So I know that there is a wiring diagram in Appendix F of the -20 TM, I already looked at that. I got stuck on the trail the other day after shutting off the truck and figured out that the small red wire going to the starter solenoid wasn't powering the solenoid. We jerry rigged a wire from that...