HMMWV Expedition Build Thread

[hmmwv]

I'm looking forward to many exciting adventures!

I have a 1992 AM General HMMWV (Humvee) that I will converting into an expedition vehicle. It will be a slow conversion but it should be quite exciting.

As of right now the Humvee has the factory drivetrain and only a few slight changes listed below.

Detroit 6.2 Diesel
Turbo400 3 speed auto
NP241 All Time Transfer Case
Differentials and portals are all stock
I changed the wheels to the 24 bolts variety along with adding 38.5" Super Swamper TSL SX's
Mile Marker 12K lb winches front and rear along
Shelf unit behind the "doghouse"
Jeep CJ Seats
Simple bluetooth stereo
Added a 12v electric system to run alongside the 24v system

I still need to install my air compressor along with air tank and do some general cleanup.

I'll keep you updated as the build progresses.

 

[JakeH]

That will be awesome! What kind of highway mileage does that beast get?

 

[Coachgeo]

had a friend back in the 90's with a millitary hummer as his offroad rig. He discovered the need... and had enough money too 1. Have on 24hour call a full-time mechanic with a lot of Hummer experience and vehicle that can drive out to recover him. 2. A HUGE Cell phone antenna with expanding mast to raise high (12 feet?) in order to be able to call said mechanic when he broke down off road. Why the Mast??? Cause it broke down that often!!!. Just an FYI.

 

[hmmwv]

I would post pictures but it says I can't add a link. Probably because i'm new here.

JakeH - 10mpg with the Detroit Diesel but i'll do a motor swap later to get better mpg and a more modern drivetrain.

Coachgeo - i've had it for over a year and i've done some pretty serious trail rides with no breaks yet. I have heard of people having trouble with them but if you know what you're driving and know how to drive it you really shouldn't break. I mean it's been through 3 wars being driven like a rental by young marines and it's survived. Not much I can do to harm it at this point. Most people break them because they drive them like they're invincible and they are really just 1-ton chevy trucks with aluminum bodies on portal axles.

 

[toylandcruiser]

had a friend back in the 90's with a millitary hummer as his offroad rig. He discovered the need... and had enough money too 1. Have on 24hour call a full-time mechanic with a lot of Hummer experience and vehicle that can drive out to recover him. 2. A HUGE Cell phone antenna with expanding mast to raise high (12 feet?) in order to be able to call said mechanic when he broke down off road. Why the Mast??? Cause it broke down that often!!!. Just an FYI.

They're not that unreliable. I drove all over in them while in the army and never had an issue

 

[bigskypylot]

had a friend back in the 90's with a millitary hummer as his offroad rig. He discovered the need... and had enough money too 1. Have on 24hour call a full-time mechanic with a lot of Hummer experience and vehicle that can drive out to recover him. 2. A HUGE Cell phone antenna with expanding mast to raise high (12 feet?) in order to be able to call said mechanic when he broke down off road. Why the Mast??? Cause it broke down that often!!!. Just an FYI.

There's always an "expert"

 

[hmmwv]

Do I have to have a certain number of posts before I can post a pic? This threads gonna get real lame real quick without pictures.

 

[hmmwv]

 

[(none)]

I commend you on your choice. I was a light/heavy/M1 mechanic in the army. Those things take a lot of abuse and keep moving. There isn't much to them. They do have a great "cool" factor to offset how terrible they are to drive. Biggest issue we had with them was overheating, so just keep an eye on the temp gauge. As i'm sure you already know, the cooling fan is actuated by the controller/relay on the driver's side under the hood. Just disconnect the wires and the fan is always on. Sucks the fuel mileage down even more and makes it even louder, but will keep that motor cool until you can repair it.

 

[chilliwak]

What a cool looking rig Mr Hmmwv! That rig has lots of potential. I will be interested to see what you do with that rig. Please post lots of pics and welcome to the site. Cheers, Chilli.....

 

[Dock Rocker]

I built one up and sold it. If you don't have the newer alternator with the 12 volt take off start collecting up parts. It's worth it. The only down side is if your compressor pulls more than 40 amps you are going to have to put in at least one more battery. That alternator was only meant to charge the system so that they could run a 12v transmission controller for the 4L80 E. GM wouldn't make them a 24 volt option with overdrive.

Collect up a half shaft for each corner (they are all different). You will eventually break an axle. They will all fit nicely in a 40mm ammo box if I remember correctly.

Remember to keep it under 55. Those 6.2's do not like high RPM's. 60 is pushing it. 65 for any time could result in a motor swap.

There a couple of hmmwv pro's in the Atlanta area. Just search for the beast hmmwv. Also get to know Blain at http://www.usedh1.com/ he has the hook up on hard to find parts and pieces.

Also the best thing I ever did with mine was to add a 12K hydraulic winch front and back. By far my best mod.


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[hmmwv]

Thanks! I haven't had any overheating issues but i''ve been told many times that's what gets you. I disconnected the full throttle fan cut off switch but I didn't know about unplugging the controller to make them run all the time. I won't do that on a regular basis but in a pinch that's great to know. Hopefully in the next 6 months i'll put an LS motor out of a 2500 chevy. It will get rid of the diesel issues and hopefully run a little quieter/smoother for long rides. At the same time i'll go to a radial swamper so they ride a little smoother on the interstate. It will still be hard to break that 65mph barrier because of the gearing but maybe I can smooth out the wide a little.

I commend you on your choice. I was a light/heavy/M1 mechanic in the army. Those things take a lot of abuse and keep moving. There isn't much to them. They do have a great "cool" factor to offset how terrible they are to drive. Biggest issue we had with them was overheating, so just keep an eye on the temp gauge. As i'm sure you already know, the cooling fan is actuated by the controller/relay on the driver's side under the hood. Just disconnect the wires and the fan is always on. Sucks the fuel mileage down even more and makes it even louder, but will keep that motor cool until you can repair it.

 

[hmmwv]

Great info. I actually did do the 200amp 24v/ 60amp 12v alternator swap and added a third battery under the rear passenger seat that currently runs my small bluetooth stereo and will run my 4l80 trans controller and v8 swap starter/ignition. I've got a front drive shaft but i'll start collecting the others as backups.

I just finished installing 12K winches front and rear. Haven't even had a chance to stretch the cables yet.

Thanks for all the great info. I'll check out your sources.

I built one up and sold it. If you don't have the newer alternator with the 12 volt take off start collecting up parts. It's worth it. The only down side is if your compressor pulls more than 40 amps you are going to have to put in at least one more battery. That alternator was only meant to charge the system so that they could run a 12v transmission controller for the 4L80 E. GM wouldn't make them a 24 volt option with overdrive.

Collect up a half shaft for each corner (they are all different). You will eventually break an axle. They will all fit nicely in a 40mm ammo box if I remember correctly.

Remember to keep it under 55. Those 6.2's do not like high RPM's. 60 is pushing it. 65 for any time could result in a motor swap.

There a couple of hmmwv pro's in the Atlanta area. Just search for the beast hmmwv. Also get to know Blain at http://www.usedh1.com/ he has the hook up on hard to find parts and pieces.

Also the best thing I ever did with mine was to add a 12K hydraulic winch front and back. By far my best mod.


Sent from my iPhone using Tapatalk

 

[ExplorerTom]

Interested to see how it evolves.

 

[Expedition.Report]

Looking forward to seeing this build