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1985 Chevy M1009 (CK5 build thread part 2)

Overview Gallery Discussion
Thermostat crossover gaskets:
I had a slight coolant leak on the front passenger side of the 6.2, and at first I thought head gasket, but I watched it for a few weeks and saw it was the thermostat crossover gasket leaking. I started by ordering some standard blue Fel-Pro gaskets, but then I found some on Quadstar Tuning's site that were for a Humvee and looked a lot better, with a built in O-ring, so those got the nod:
IMG_20250316_130712069-1.jpg
Everything came right apart, but looked ugly:
IMG_20250316_115415563_HDR.jpgIMG_20250316_115431549_HDR.jpgIMG_20250316_115420493.jpg
One snafu I ran into is I bumped the vacuum fittings on the Vacuum Regulator Valve (VRV) with the socket extension and broke off the nipple:
IMG_20250316_115431549_HDR-1.jpg
IMG_20250316_115447096_HDR.jpg

So, I just bypassed the VRV for now, and looped the vacuum hose straight back to the steel line that runs to the trans. A test drive when I got it buttoned up revealed that everything was working fine, although the trans seemed to run through the gears quicker. The kickdown shift was unaffected. I will eventually replace the VRV, unless I can find one for parts and steal the fitting piece. Or maybe epoxy it back together.
I also replaced the water pump bypass hose with some fresh Gates 5/8" heater hose, and replaced the upper and lower radiator hoses with new units from AC Delco.

EDIT: I just found a used VRV on eBay, and snatched it up. The description said it was AC Delco part # 14057219, and came off a CUCV. If the epoxy doesn't work, I will swap in the used piece.
 
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This is a popular mod people do.

paradoxbydesign.com

Military CUCV Hybrid (HMMWV Crossover) Cooling System Upgrade kit

PARADOX Military CUCV Hybrid 6.2lts COOLING UPGRADE KIT (patent pending)This is simply the best bang for the buck upgrade you can make to your truck, period! Must do before any performance or horsepower mods.All CUCV trucks with GM Detroit Diesel V8 6.2 engines all share an inherent design flaw...
paradoxbydesign.com paradoxbydesign.com
 
Cucv_M1008 said:
This is a popular mod people do.

paradoxbydesign.com

Military CUCV Hybrid (HMMWV Crossover) Cooling System Upgrade kit

PARADOX Military CUCV Hybrid 6.2lts COOLING UPGRADE KIT (patent pending)This is simply the best bang for the buck upgrade you can make to your truck, period! Must do before any performance or horsepower mods.All CUCV trucks with GM Detroit Diesel V8 6.2 engines all share an inherent design flaw...
paradoxbydesign.com paradoxbydesign.com
Click to expand...
I have seen that kit, but the glow plug system on my M1009 uses a temp sensor in the back of the drivers side cylinder head, right where one of those steam ports in the kit would go:
IMG_20240511_151027051-1.jpg
:dunno:
 
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Well, I have owned the M1009 for a year now, and looking back on this thread, I sure have been busy making improvements! I have definitely been enjoying it.
IMG_20250329_165014350.jpg
Today I was able to get to a few things before the rain came back. I scored a new used VRV off of eBay, and swapped it on. I can report that the TH400 is happy again, holding gears and shifting like before.
IMG_20250329_111132866.jpg
I had also noticed that the belts weren't looking that good, and I had ordered a set from @hillbillywizard awhile ago. They make it a no brainer to get the right belts for a CUCV, as they sell all three together. Swapped them on today too:
IMG_20250329_114428414.jpg
You can also see in pic below the brand new oil cap form @hillbillywizard , to replace to original that liked to weep.
IMG_20250329_123834617_HDR.jpg
A since I was at it , I swapped on a set of Yukon Hardcore diff covers. I do have a set of lockers to install, a Grizzly for the back and a Spartan for the front, but I will get to that later. The Lube Lockers I had installed before came in clutch, and made the cover swap quick, since they are reusable and there is no RTV to clean up. I have put over 300 miles on the M1009 since the one ton swap, and the gear oil that was new then had some discoloration to it now, even though I tried my hardest to get the axles clean back in November. So I will think of this as almost a gear oil flush, and not worry about the cost of the Lucas 80w/90.
IMG_20250329_152947100_HDR-1.jpg
IMG_20250329_153039896_HDR-1.jpg
And, I knew I couldn't get away with an axle swap without brake work, as the left rear wheel cylinder started leaking. Shopping around, I saw there were two different wheel cylinders available, the difference being the bore size, 1.188 vs. 1.063. I ordered one of each, and will return the incorrect size. After all, they were 10 or 12 bucks each from the jungle site for AC Delco's version.
 
cheavyk10 said:
Well, I have owned the M1009 for a year now, and looking back on this thread, I sure have been busy making improvements! I have definitely been enjoying it.
View attachment 500905
Today I was able to get to a few things before the rain came back. I scored a new used VRV off of eBay, and swapped it on. I can report that the TH400 is happy again, holding gears and shifting like before.
View attachment 500906
I had also noticed that the belts weren't looking that good, and I had ordered a set from @hillbillywizard awhile ago. They make it a no brainer to get the right belts for a CUCV, as they sell all three together. Swapped them on today too:
View attachment 500907
You can also see in pic below the brand new oil cap form @hillbillywizard , to replace to original that liked to weep.
View attachment 500908
A since I was at it , I swapped on a set of Yukon Hardcore diff covers. I do have a set of lockers to install, a Grizzly for the back and a Spartan for the front, but I will get to that later. The Lube Lockers I had installed before came in clutch, and made the cover swap quick, since they are reusable and there is no RTV to clean up. I have put over 300 miles on the M1009 since the one ton swap, and the gear oil that was new then had some discoloration to it now, even though I tried my hardest to get the axles clean back in November. So I will think of this as almost a gear oil flush, and not worry about the cost of the Lucas 80w/90.
View attachment 500910
View attachment 500911
And, I knew I couldn't get away with an axle swap without brake work, as the left rear wheel cylinder started leaking. Shopping around, I saw there were two different wheel cylinders available, the difference being the bore size, 1.188 vs. 1.063. I ordered one of each, and will return the incorrect size. After all, they were 10 or 12 bucks each from the jungle site for AC Delco's version.
Click to expand...
Sounds like a good busy day of getting it ready for Blazer Bash.
 
Had to dig into the brakes, the leaking wheel cylinder was loosing a lot of fluid. Turns out I had the 1.063 sized wheel cylinder.
IMG_20250405_123615895-1.jpgThe brakes were gross too, lots of grime to clean up in there. And since I had to crack the lines, I went ahead and installed the braided stainless steel rear line l got with the axle deal. The factory rubber line wasn't in the best of shape, and was a bit too short. I had already bent the factory mounting tab backwards to gain some room. The braided line was kinda long so I looped it to the front of the truck.
IMG_20250405_123645192_HDR-1.jpg
ORD tie rod:
I ordered up the same tie rod I have in the K10, the ORD HD 1.5" O.D. x .375" Wall DOM version. I got it with the ORD tie rod ends and got the stabilizer bracket too.
Fogged some paint on earlier this week and got it installed today. Next to the factory rod:
IMG_20250405_143246555-1.jpg
On there:
IMG_20250405_154233885_HDR-1.jpg
Its really close to the Yukon diff cover at full right lock, but clears.
IMG_20250405_152758379_HDR.jpg
Top down view of the ORD stabilizer mount:
IMG_20250405_160407013_HDR.jpg
AIso, set the toe at 1/8" with alignment plates from TMR.
IMG_20250405_144626121-1.jpg
 
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Cleaned up the tire some, and pulled the back seat. Was actually able to get the tire on the factory mount okay, I reused the wing nut and the bolt for the factory wheel. I just had to bend the wing nut a little bit and went through a stud hole in the wheel.
IMG_20250412_121256827~2.jpg
 
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Sure looks like @cybrfire has my sliders ready for powder. I ordered right away as soon as I saw the product list come back up on the DIY4X products Tech Talk page on FB. My ordered specs look like the set in the middle: angled as close to the body as possible and two inner gusset tubes. I haven't confirmed they are mine just yet, but it is still exciting.
491684591_1070963544864421_4574042468465467746_n.jpg
 
cheavyk10 said:
Sure looks like @cybrfire has my sliders ready for powder. I ordered right away as soon as I saw the product list come back up on the DIY4X products Tech Talk page on FB. My ordered specs look like the set in the middle: angled as close to the body as possible and two inner gusset tubes. I haven't confirmed they are mine just yet, but it is still exciting.
View attachment 502016
Click to expand...
I'm jelly
 
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