CUCV Technical Info
Here is information I have collected while working on my m1009, but this information can be used for m1008,m1028, m1028A, and any of the cucv series.
The CUCV (Commercial Utility Cargo Vehicle) was manufactured by General Motors for the U.S. government from 1984-1986. They were built from the heaviest duty parts of GM’s light commercial truck division. The M1009 is a stripped down blazer that has been modified to reach a 3/4 ton load rating while all other CUCV series trucks are rated at 1 1/4 ton.
Government Issued Manuals Regarding the CUCV:
- TM 9-2320-289-10 — Operators Manual
- TM 9-2320-289-20 — CUCV Maintenance Manual
- TM 9-2320-289-34 — Intermediate Maintenance Manual
- TM 9-2815-237-34 — 6.2L Engine Maintenance
- TM 9-2320-289-20P — Parts Manual
- TM 9-2320-289-34P — Intermediate Parts Manual
- TB 11-5820-890-20-77 — Radio Install
- LO 9-2320-289-12 — Lube Order
- TB 43-0147 — Paint Specs
- Dot 5 silicone brake fluid (Level should be 1/4″ below top)
- Power Steering fluid can either be transmission fluid or standard power steering fluid. Do not mix.
- Any standard air filter designated for use in a K5/K30 should work
Batteries and Alternators
- Group 31 or 6TLs (Original)
- Any 800+ CCA batteries would work
- Dual 100Amp Alternators wired in series for 24V
- Passenger side alt MUST BE ISOLATED GROUND!
- 6.2L Naturally Aspirated Detroit Diesel V8
- Injector Pump
- Stanadyne Roosa Master DB2 (Click for detailed information)
- The estimated life is 100,000 miles. However, in a 25 year old vehicle, the seals are worn out.
- If you are leaking fuel from the bell-housing cover, it is likely drain off from the IP through a hole in the rear of the engine compartment
- The first seals to wear out are normally the throttle-shaft seals which are inexpensive but a time consuming job to replace in which the intake must be removed. Also the wearing of these seals normally corresponds with the wearing of the pump itself and it may be better to rebuild or replace the pump if it is original. Rebuilt pumps are usually in the $3-500 range plus a core charge if you don’t provide them with your old one. Getting your IP rebuilt is probably the best thing you can do for your vehicle.
- 7 Quart Oil Capacity
- Fuel Filter
- NAPA# FIL3136 or FRAM # P3940A
- SAE 30 for diesel for temperatures above 40* Fahrenheit
- 15W40 for diesel for lower temperatures
- Filter is FRAM# PH5, NAPA# FIL1092, ACDELCO# PF1218CL, K&N# HP-3002
- NAPA 381-190 or Autozone 42995 or Orielly 42995
- 180* for hot areas works well and 190* is the original supplied part
- Glow Plugs
- Wellman 070 or AC 60G
- Relay– NAPA# ST85
- Control Card http://www.flmv.net/FLMV-CUCV.htm
- Belts (Not for M1010)
- Driver side alt Gates# 7575/Dayco# 15580
- Passenger side alt Gates# 7483/Dayco# 15490
- Power Steering Gates# 7448/Dayco# 15455
- Injector Pump
- Turbo-Hydramatic 400 (Th400)
- Dextron III Oil
- Approx 4 quarts
- Replace filter ever 2 years or 24,000 miles
- NAPA# ATP14558, FRAM# FT1020A (w/gasket)
- If running oversize tires or towing an external cooler is HIGHLY recommended.
- M1009/M1008/M1028/M1010 uses a NP208 aluminum chain driven transfer case.
- M1031 uses a NP205 cast iron gear driven transfer case with PTO abilities.
- Level should be 1/4″ below filler plug
- Dextron III fluid
- 5 quart capacity
- 10 bolt axles front and rear with 3.08 gears and a Gov-Loc in the rear (Not Dana 60 front and 14 bolt rear like some believe)
- All other CUCV’s Dana 60 front/14 Bolt FF rear with Detroit locker and 4.56 gears (some have a true-track locker in the front as well, but it is rare)
- Front Capacity 4.5 Quarts
- Rear Capacity 5.4 Quarts
- M1028 needs GM additive
- The right toggle switch moves power to the service lights, horn, dash, etc (up position) or to the blackout lights (down position). Pull it out and flip it up or down.
- The left switch turns on the blackout drive light. Flip it up or down; it will return to center position.
- If your lights suddenly don’t work, check the right toggle switch.
There are multiple options to get a tach installed in a CUCV the simplest being a digital tiny tach (http://www.tinytach.com/tinytach/diesel.php) the fuel injection lines on the CUCV are 1/4″ OD. The CUCV alternators also have a tach output on the alternators so that can be used for certain tachometers as well.
CUCV Fuse Box:
Some information on this page from http://www.steelsoldiers.com