wrench party this weekend (and next, and next.....)

[mjeff87]

If anyone's around this weekend and wants to wrench a bit south of the river (Chester), or just come hang out and drink beer, project 4.0 swap is getting underway. Also, another MJ buddy of mine from Waynesboro is (hopefully) coming down with his MJ to do some work on. I bit the bullet and finally rented a 20X30 storage facility for the next couple months. My goal for Saturday is to pull the front clip and radiator, and the 2.5/tranny/TC. If I get that done, I'll pull the underhood wiring harness and ECU on Sunday and start cleaning up the engine bay to get it ready for the 4.0.

I might toss a pork shoulder on the grill/smoker early AM for dinner, and pick up some local corn too.

Jeff

[littlejohn]

I'm not too far- I live off Beach Road.

PM me an addy and I'll try to stop by to lend a hand.

John

[mjeff87]

We'll be down at the storage facility, which is about a mile or two from my house. It's on Jeff Davis Hwy. just south of Wood's Edge Road....can't recall the name of it now. If you're in the area call me on my cell 804-720-3106 and I'll meet you at the gate and let you in.

Bud Lights will be on ice, plenty of them......:cheers:

Jeff

edit: Ample Storage, 16342 Jeff Davis Hwy

[mjeff87]

Got the driveline pulled, as planned....

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/clipoff.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/engineout.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/drivelineout.jpg

[mjeff87]

Got the underhood wiring harness and vacuum harness pulled out today:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/harnessout.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/harness.jpg

Buncha 2.5 stuff:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/oldstuff.jpg

The workshop:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/cleanshop.jpg

[Ace4wd]

Looking nice.

[tjbliley]

Don't forget me when you go to parting out that 2.5 and all the stuff with it.

[mjeff87]

Pat has laid claim to the engine in exchange for the 4.0 he gave me, but I have another one up in PA I need to bring back down here. You and Chuck can argue over the rest:D but I've got plenty for both of you......

Jeff

[Ace4wd]

Who is this Chuck you speak of ?

[mjeff87]

you remember him......he was the fool who ran off and got married:tard: (no offense Annie...)

bought a house with a nice big 2 car garage to work in and hasn't had a wrench in his hand in over a year:lmao:

[tjbliley]

You forgot that he found time to make her his "Baby Momma".

[mjeff87]

Started working on the 4.0L I got for free this weekend.

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture017.jpg

Pulled and painted the oil pan, and put new freeze plugs in it

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture003.jpg

Pulled the head off and took it to the shop to hot-tank it have the broken exhaust stud fixed. Should have it back tomorrow

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/headoff.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/headpff2.jpg

Installed a new RMS and a Felpro 1 piece pan gasket

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/rmsandpangasket.jpg

I’m reusing the headbolts (and will be painting the tops), so I cleaned them up on the bench grinder

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/cleanupheadbolts.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture015-2.jpg

Started putting things back together. At this point, I have to wait for the head before I can assemble any more

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture015-2.jpg

Installed an HO compressor bracket and mounted the compressor (for OBA)

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture014-2.jpg

Where it sits now

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/reassembly.jpg

[WildTurkeycj8]

Nice work. What shop did you send the head to?

[mjeff87]

not really an advertised shop, just a couple of brothers that run out of their redneck garage down in Dutch Gap.....they redid a head for me for a Ford Escort I pulled out of CAR when mine dropped a valve seat.

Hot tank+new oil seals+drill out the snapped stud that I tried to drill out and FUBAR'd.....$50. I ain't complaining:D

Jeff

[mjeff87]

Got the head back from the good ‘ole boys shop yesterday, hot-tanked and broken stud (with a broken drill bit stuck inside of it too) milled out and replaced with a helicoil. Also test-fitted an RE trackbar brace that for the most part all lines up. Not sure if it will be in the way when I go to reinstall the driveline, but it’s so easy to fit in right now with nothing (like an engine) in the way…..

Repair:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture016-1.jpg

Cleaned up head (pushrods are off soaking in some solvent at the moment):

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture018-1.jpg

TB brace:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture.jpg

Now I can finish bolting the engine back together, and hopefully get the whole driveline back in this weekend. Next weekend is travel to PA for the wifey’s family reunion, so no work on the MJ after this weekend for a couple of weeks :sad:

Jeff

[cmcolfax]

[thread hijack]

Who is this Chuck you speak of ?


you remember him......he was the fool who ran off and got married:tard: (no offense Annie...)

bought a house with a nice big 2 car garage to work in and hasn't had a wrench in his hand in over a year:lmao:

Phockers.


You forgot that he found time to make her his "Baby Momma".

That only took a coupla minutes.

Heh.

[/hijack]

Looks good Jeff.

I am jealous.

-cmc-

[mjeff87]

Small progress made on Saturday, my weekend got cut short.

reinstalled head:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/headreinstalled.jpg

put the manifolds, new injectors and fuel rail on:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/manifoldsinstatlled.jpg

new fancy FelPro valve cover gasket (it better not leak, it was $51!!!):

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newVCgasket.jpg

new power steering pump, plugs/wires/cap/rotor, oil and filter, serpentine belt:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newPSpumpandassembled.jpg

Basically, the engine is ready to drop in. I stopped down last night to drop off some parts and noticed the oil pan gasket was leaking a couple drops right in the front under the HB :mad: Snugged the pan bolts up and cleaned the whole area up and will recheck tonight after work to see if it’s still leaking (hopefully not)……everything was SQUEAKY clean when I assembled it, so I’m not sure why it’s leaking in the first place.

I’ll be at it all weekend coming up, my wife is going out of town and I got a reprieve from going with her. Anyone’s welcome to stop by and help or just hang out…..

Jeff

[mjeff87]

Weekend progress (cut short by work :mad:) Ran into a problem with the pilot bearing being wrong….I’m heading to the parts store today to get what I hope is the correct one. Once I get it, I can bolt the new flywheel, clutch, and tranny to the engine and set it all in place (maybe tonight).

Got the 4.0 harness and new throttle cable installed:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newharnessinstalled.jpg

Swapped HVAC fans because the connector was different:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newHVACfan_connector.jpg

4.0 ECU installed, and only had to make one splice, everything else connected right up:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newECUinstalled.jpg

Had to swap the heater control valve (2.5 routes coolant thru the intake manifold):

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/heatercontrolvalve.jpg

Moved onto the tranny, new slave/throwout, CPS and output seal:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newthrowout_slave.jpg
http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/newCPS.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/neoutputseal.jpg

Cleaned up the dust shield:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/cleanedupdustsheild.jpg

Waiting on the pilot bearing now:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/100Aalternator_harnessinstalled.jpg



All I really need now are new heater and radiator hoses and a muffler (new cat converter in hand, too). Also have to splice the 4.0 fuel lines into the 2.5 ones, and figure out where to mount the coolant overflow bottle (once I get the engine back in).

Jeff

[mjeff87]

I picked up a steel sleeve bushing yesterday that other people have used, and it didn’t work. It has the right OD to fit in the crank, but the wrong ID (still too large to fit the input, and too small to press the stock needle bearing in). Went by the parts house and we rummaged through a bin of bushings and I got a brass one one that will work. ID is perfect, but the OD is just a tad too big to fit. I dropped it by the machine shop yesterday at lunch to have it turned about .008-.010. Picking it up today and popping it in the freezer overnight to press in tomorrow.

Jeff

various parts, left to right: stock needle bearing, brass bushing I’m using, steel sleeve that didn’t work (Dorman p/n 14674):

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2255.jpg

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2254.jpg

[mjeff87]

Interesting development here…..I installed the brass bushing (that’s been sitting in my freezer for the last 10 days) after work last night. It went in without a hitch. Then I proceeded to install the new flywheel and got lucky because I had a spare set of bolts from a clutch job in the past. The flexplate bolts (remember, this engine was in front of an AW4 at one time) are not long enough. Got that done and went to install the new clutch……..and it’s the wrong #%#*&! one. Parts store gave me an AX5 clutch not an AX15.

I’m taking it back today after work and exchanging it, and I’ll bet you any money that the pilot bearing that comes in the AX15 kit will be a perfect fit. The one I have now is for an AX5, which presses into the flywheel, not the back of the crank.

New bushing installed:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/bushinginstalled.jpg

Flywheel installed:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/flywheelinstalled.jpg

Flywheel versus flexplate bolts:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/flywheelbolts.jpg

[mjeff87]

Made some progress this weekend, but not as much as I’d have liked to. Got the correct clutch kit (with the correct pilot bearing), swapped the bushing for the bearing and got the clutch and tranny installed on the engine. Jerry and his son came down on Saturday and we got the driveline in. I forgot to pick up the plate for the transmission that the mount attaches to, so I had to hit the junkyard this morning and pick one up. Got the plate, mount, AX15 shifter, and a clutch master cylinder for $30. Futzed around with the crossmemeber for about an hour trying to get everything lined up and realized I had it installed backwards…flipped it around, had to pound out a stud on the passenger side framerail that didn’t line up with anything, and bolted it all up. Hung the transfer case, cleaned up the shop and called it a day. I got smashed on tequila Saturday night and felt like crap all day today.

Couple pics:

Correct pilot bearing, installed

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture021.jpg

New clutch kit

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture022.jpg

Tranny bolted on, ready to install

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture023.jpg

Going in

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture024.jpg

Finally installed and all bolted up

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/Picture025.jpg

[TEACH JP]

I am so jealous right now. Looks good!

[mjeff87]

Made some good progress last weekend…I should have it running by Saturday afternoon. Jerry came down and gave me a hand splicing the NSS wiring and helping me swap out tranny crossmembers. A note to anyone installing an AX15 in their rig if there isn’t one there to begin with……all the transfer case shift linkage parts except the shifter handle assembly are different (specific to the AX15 ONLY) as well as the #%*#@$ tranny crossmember, which is diveted out in the center where the mount goes. If you use any other crossmember the TC linkage will not line up and your catalytic converter will be kissing the floorboard. Found all that out the hard way, but two trips to the junkyard later all is well.

Got the NSS wiring spliced, swapped the fuel lines, reinstalled the windshield washer reservoir, got the 2.5 coolant overflow bottle installed and happy with the wiring harness (eliminated the ballast resistor and have to relocate the EGR solenoid). Got the battery/alternator wiring all tied in and reinstalled the battery. Turned the key to check for fuel leaks and to test the starter circuit……starter works and engine spins but the battery needs to be charged. The fuel pressure regulator is puking fuel all over the place at the seam where the two pieces are crimped together. Will be installing a new one this week. Ended up stopping work on the engine and installed the trackbar brace, pulled the rubber cargo mat and reshot the floor with spray-on bedliner. I have a new cargo mat but I think I’m going to leave it out for now and see how loud it is. I can always pull the seats out and install it later.

Couple pics:

Spliced the NSS wiring (well, Jerry did…..:D)

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2331-1.jpg

gas pedal is different between a 2.5 (left) and 4.0 (as well as the throttle cable)

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2326.jpg

cover for the tranny hump is different (AX15 on R)

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2327.jpg

RE trackbar brace installed (what a PITA!)

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2332.jpg

fresh coat of bedliner on floorboards (you can see the repairs I made a couple years ago on the driverside……there was nothing there)

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2333.jpg



couple random pics……

shot from underneath:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2354.jpg

new TC installed:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2353.jpg

shot of the AX15 crossmember, showing the divet in the center where the mount attaches:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2355.jpg

got the flange welded up on the new cat and got it installed:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2357.jpg

[mjeff87]

fire in 'da hole......


http://www.youtube.com/watch?v=gGmgiizV5rY

:rock:

Jeff

[Ace4wd]

:hellyeah:

[MACK]

:cheers:

[mjeff87]

put a glasspack on it with a turndown tip:devilfing

Drove it around a bit this morning, the difference is night and day.

Jeff

http://smg.photobucket.com/albums/v220/mjeff87/4L%20conversion/?action=view&current=40running_2002.flv

[cmcolfax]

put a glasspack on it with a turndown tip:devilfing

Drove it around a bit this morning, the difference is night and day.

Jeff

http://smg.photobucket.com/albums/v220/mjeff87/4L%20conversion/?action=view&current=40running_2002.flv

DAYUM.

I was gonna ask you what you had on there for a muffler... sounded tough!

Nice work.

Sorry I couldn't help.

-cmc-

[mjeff87]

Sorry I couldn't help.

-cmc-

quite understandable :cheers:

If you can get away for a couple hours this weekend, there's a bunch of us MJ guys getting together down here south of the river for a junkyard/beer swilling adventure. Gimme a call...

Jeff

[Benz0]

noice! :cheers:

[mjeff87]

Forgot to post this earlier……pic of the difference between the 2.5 and the 4.0fuel pumps (2.5 one is the smaller one on the bottom). I was going to try and see if the 2.5 pump would have enough psi to fire but went ahead and swapped everything out beforehand. I wasn’t sure it was going to start to begin with, and didn’t want to add a variable to the equation if I had to troubleshoot.

differences:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2366.jpg

because MJ fuel pump assemblies have a tendency to crack where the metal lines pass through the mounting plate, and they are universally unavailable anymore, I decided to add a bit of JB weld to the lines on the new assembly before putting it in as a safety measure:

http://img.photobucket.com/albums/v220/mjeff87/4L%20conversion/IMG_2367.jpg