Your original description was the voltage gauge is flickering, so this does not necessarily mean your GP are cycling - it could be a short elsewhere. If your WTS light is cycling (with your voltage flickering) then something is cycling the GP controller (as snicklas said).
If you are replacing...
You can spend any amount of money getting high end rebuilds (stage, 1,2,3...) depending on the power you want to put in front of it, but I think all rebuilds address the original weaknesses. I suggest pick a reputable rebuilder and let them decide what is best for you.
I know when mine failed...
My preference would be to install a new gear but I have successfully changed the sector shaft seal; a nice way to get it out is to remove the snap ring, start the truck and 'bump' the steering stop. The pressure spike should blow the seal out. Shut it down so you don't ruin the pump...
Mine is connected to the FSS but I did not need a relay. I am using a marine Walbro pump, very little current draw.
I recently installed hydroboost so will be installing an electric vacuum pump and junking the belt pump. I will be installing one relay to power the fuel and vacuum pumps...
Been a while but I think I fixed mine with some JB weld and a screw tapped into the broken stud. I found that the bottom pivot fills with crap and gets tight... probably the cause of the breakage.
Check out the details in my D60 swap post. I think I did everything that you are looking to do (seals and steering). Part number, prices and everything is available there. Link in my signature below. I only used XRF steering, Spicer u-joints and axle parts. Consider "the cure" while you are...
I put an Alpine CDE-143BT in mine. It has a microphone - I dressed the wire behind the interior trim and located the mic on the DS visor. Radio works very well, BT is awesome, has a front USB input.
Just food for thought... Dragging logs out may not be the best way if you are planning on bucking it up for firewood. Dragging will fill the bark with grit and be really tough on your saws. I also think that winching will take a lot of time; it might be more efficient for you to cut into...
^^+1 I think the E series came from the factory with different size batteries (one was not a lawn mower battery though ;burnout)
I stuck with stock size batteries from Costco (Kirkland brand). -20C this morning and fired right up, no block heater, batteries are three or four years old. Good...
^^+1 Go over all the wear parts. This is a big job but the only way to get it right (or put a D60 in!) You need to change the pivot bushings also.
I recommend poly bushings; google Energy Suspension.
I would replace the bed bolts (well the front ones anyway) with an eye bolt or some other anchor. Stupid that trucks were ever made without in-bed tie-downs.
I changed mine (box on). Not too bad of a job. I was able to reach the pickup and return lines and release them, PITA though. Would have helped to have 4" more slack! You can siphon any remaining fuel out.
If you are going to lift the box off then I would check the pick up and return lines...
I received a huge red warning that this forum is a "deceptive site" and will try to steal your identity, etc. Apparently this is some new deal that Google is implementing to "protect their users". some info here https://aw-snap.info/articles/phishing.php
Apparently using ads can cause this...
The radius of the TTB is not the same as the radius of the relay rod. Ok, in a tight system that won't matter so much but any slop in your tie rods, joints, and the TTB pivot etc will complicate the issue.
Here is a more detailed explanation.
https://www.youtube.com/watch?v=_ilnd5wQEpg
I suggest pulling the return line off the last cap (where it heads back to the FSV) and put a longer hose on it. Easy to start it up and check for pressure. Then run it into a fuel can for a short trip and see if you still get leaks. This would also tell you how much flow you are getting back...
Really depends on what you are looking for. I find the States is better for finding quality parts - IP, injectors, GP's. In Canada you are stuck with questionable rebuilds and cheap China components. I do not like NAPA, I have have some good luck with Carquest but most of my significant...
I thought I would post some details of how I balance my own tires using tire beads (using off the shelf balancing beads and an alternative).
For those who are not familiar with tire balancing beads here is a good video that demonstrates how they work...
Alright... time for a followup on this! Anyone complete their installation? ;Poke Winter is coming so better get under your truck while the get'n is good!
Yikes! Mine had been shifting harder, delayed shifts, etc for a while. Then one day it 'freewheeled' (no gears forward or reverse). $3400 fixed it. 320,000 km is about right for the E4OD to wear out it's consumables. Rebuild should last longer than the original due to upgrades.
Oh ya...
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