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Old 09-29-2010, 02:24 AM   #1
K5cucvEOD
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Default m1009 CUCV K5

Well this is my first build. I'm starting with an 1984, m1009, K5, 6.2l diesel(blown), 4" lift, TH400, NP208, and 10bolt/3.08gears. I picked up an m1008, k30 downer truck at an auction. 1ton axles ( Dana 60/14ff w/locker), good running 6.2l with only 29k on it, a th400/np208. All that is going into the K5. I already have a Banks turbo kit that's going on as well. Just ordered a crossover steering kit from sky-manufacturing. Just need a 2x4 steering box. Ordered zero rates and kingpin rebuild kit from offroad designs. Once infer the new drive train in I will need to come up with some wheels and tires. I drained the d60 and put in new spicer u-joints today. I know I'll have to break it all down again to do the kingpins, but needed to get started. Will try to post pics soon. So here we go
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~'84 CUCV M1009 6.2L w/Banks Turbo, th400/np208, D60/14ff w/Detroit locker 5" Lift on 36' Irok's

~Parts truck~ '85 CUCV M1008,
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Old 09-29-2010, 02:00 PM   #2
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Default Re: m1009 CUCV K5

Let me know how you like the sky crossover kit... looking at getting the same thing for my CUCV
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Old 09-29-2010, 03:25 PM   #3
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Default Re: m1009 CUCV K5

hey doc, pm smee907 on here, he can hook you up with a great deal on a complete crossover kit for a great price.
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Old 09-30-2010, 08:09 PM   #4
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Default Re: m1009 CUCV K5

Sounds like great headway so far!
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Old 10-01-2010, 10:26 AM   #5
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Default Re: m1009 CUCV K5

Here is a pic of what I'm starting with.
I went through the D60. Changed out u-joints, fluid, repacked all bearings. And touched them up a little.
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~'84 CUCV M1009 6.2L w/Banks Turbo, th400/np208, D60/14ff w/Detroit locker 5" Lift on 36' Irok's

~Parts truck~ '85 CUCV M1008,
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Old 10-01-2010, 09:22 PM   #6
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Default Re: m1009 CUCV K5

I have pulled the trans, t-case, and engine from the donor truck. Next I'm going to drop the oil pan, replace the gasket, then start bolting on the turbo.
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~'84 CUCV M1009 6.2L w/Banks Turbo, th400/np208, D60/14ff w/Detroit locker 5" Lift on 36' Irok's

~Parts truck~ '85 CUCV M1008,
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Old 10-05-2010, 06:51 PM   #7
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Default Re: m1009 CUCV K5

New engine is in. Turbo is bolted on. Just a few minor things left to hook up to get it running. Got in all my parts to rebuild the d60 kingpins. Also got 1" zero rates from Offraod designs.
[IMG][/IMG]

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Old 11-26-2010, 08:26 PM   #8
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Default Re: m1009 CUCV K5

[/IMG]
tore down the D60 all the way. The king pins had a lot of scoring on them. So everything got replaced. I found a lug nut that fit the king pin and a 3/4in drive impact and they came right out. [/IMG]
I used pirate4x4's D60 rebuild post as a guide to tare the axle down and put it back together. Good info.
[/IMG]
New king pin
[/IMG]
[/IMG] the driver side gets a cap and the passenger side gets the new steering arm from sky manufacturing. [/IMG]
I picked up a used 2WD steering box. Got everything bolted on. The one issue I have is the tie rod hits the crossover exhaust pipe from my banks turbo kit. Looks like I will have to bend the pipe up out of the way. My next step is putting the 14bolt in the rear. Just ordered Irok radials 36 x 13.50 x R16, on 16 x 10 procomp 98 series wheels.
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~'84 CUCV M1009 6.2L w/Banks Turbo, th400/np208, D60/14ff w/Detroit locker 5" Lift on 36' Irok's

~Parts truck~ '85 CUCV M1008,

Last edited by K5cucvEOD; 11-26-2010 at 08:30 PM. Reason: Pic did not load
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Old 12-13-2010, 09:39 PM   #9
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Default Re: m1009 CUCV K5

2WD steering box is in and working good. I had to get a different tie rod with different angles to clear the exhaust pipe. Just got the new wheels and tires from 4WheelParts.com. Cost me only $270 for shipping.
[IMG][/IMG]
36 x 13.50 x R16 on Pro Comp 16 x 10 rock crawlers.
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~'84 CUCV M1009 6.2L w/Banks Turbo, th400/np208, D60/14ff w/Detroit locker 5" Lift on 36' Irok's

~Parts truck~ '85 CUCV M1008,
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