Engine Swap - MVC style

[crazy4ink]

Well, a year after my Jeep being apart for 2 months for the SM420 swap; the Jeep is apart again. This time, part failure brought about the surgery. So in true Bionic Man fashion, "we will rebuild it stronger".

Here is what I am ripping out:
- 2004 4.0L engine
- Novak Adaptor bellhousing
- 1979 Toyota Land Cruiser clutch slave cylinder
- 1983 Ford F150 Clutch release bearing
- 1984 CJ-7 Shift Fork
- 1961 Chevy 1-ton truck tranny

Talk about a headache and a half!!!

Well, the Novak bellhousing I bought broke where the pivot ball stud was which resulted in the shift fork no longer having a fulcrum. The clutch return spring then pulled the release bearing into the clutch pressure plate and caused all kinds of carnage. We pulled 1" long pieces of shrapnel out through my starter hole.

I'm purposely not giving any info at this time, but the 4.0L and blower are NOT going back in....

Here are some pics so far. Bear in mind that these pics are the result of the MVC crew being turned loose for 4 hours on a defenseless vehicle.

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010089.jpg

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010090.jpg

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010086.jpg

Pile of parts...some to be reused and some to be sold off....

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010091.jpg

More pics to follow as progress is made.

[RnEmOvr]

is that motor junk? if so i need some parts

[RescueJP]

i need a motor lol

[notarubicon]

poor poor jeep. it better get some good lovin rob

[crazy4ink]

is that motor junk? if so i need some parts

No, it only has 32,xxx miles on it. I had it listed for sale but someone local bought it.



i need a motor lol

I've got 3 or 4 4.0Ls at the shop.



poor poor jeep. it better get some good lovin rob

It is. Built 355 SBC with TBI injection. Roller tip rockers, Magnum pushrods, Comp Cams 600-4600 RPM, double hump heads, Pete Jackson Noisey gear drive, serpentine belt conversion pullies, and some oher goodies.

[RescueJP]

how much for an engine computer and harness also i will be in the area to pick up the hard top next month

[crazy4ink]

Let me see if I have another harness. Right now, the only harness I have is the one that is modded to work with my supercharger. I should still have the one out of the '96 ZJ but I want to be sure.

[crazy4ink]

Here is the SBC that is going in. We're getting ready to set it in to mock-up/build the engine mounts

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010095.jpg


Here is the engine compartment void of all the 4.0L wiring

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010096.jpg


Here is half of the wiring from the engine compartment. Still weeding through what we need to keep and what can be deleted

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010097.jpg

[crazy4ink]

Ok, here are some updated pics for everyone...

Here is the Chevy 355 fully mated to the tranny, and sitting on the new motor mounts that we made
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010101.jpg

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010102.jpg

Notice that the 355 is sitting about 5 inches further back than my 4.0L did. We were able to keep the needed driveline angle by not removing the skid, tranny or either t-case or driveshafts while we mocked everything up.

Here are 2 pics of the serpentine belt mock-up. Have the brackets all figured out, just need time to make them out of steel.

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010105.jpg

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010106.jpg

My PSC can will be hanging off of my cross engine brace (that we need to re-make) so the angle iron is our height line marker.

[crazy4ink]

Well, since I've been slacking, here are some more recent pics....

Here is the SBC with the suburban TBI setup
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010148.jpg

We hid the computer under the cowl
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010150.jpg

Here is the new flat dash. We got it into color and clear coat
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010166.jpg

Here's the new fuel cell. I had just put an RCI fuel cell in. It was billed as a 15 gallon tank but you could only get 10 gallons in the tank. This new tank measures out at 29.9 gallons!
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010165.jpg

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010164.jpg

Here is Damien tacking the rear 4-link mounts on the Sterling.
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010178.jpg

Here is an example of how much travel the rear suspension has. Keep in mind that Damien is about 6'2" tall, the tires are 42"s, they are still on the ground and the lower links are not maxed in the axle pockets yet...
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010170.jpg

[notarubicon]

Rob that is sick bro

[JavaTee]

I LOVE build threads!! Looks great!

What's up with the supercharger? To much for the 4.0L?

Later, T.J.

[crazy4ink]

I LOVE build threads!! Looks great!

What's up with the supercharger? To much for the 4.0L?

Later, T.J.

Nah, the supercharger was great. I'm just going with a juiced-up Chevy 355. Easier to mate my SM420 to. I had a Novak aluminum bellhousing joining my SM420 and 4.0L but that broke. Easier to have all chevy pieces/parts from engine to tranny. Been trying to sell the supercharger setup for a few months now.

[crazy4ink]

Made some great progress over the last few days. Here is a glimpse of the new ride height with the sterling 10.25/Dana 60 and 42s.

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/newrideheight.jpg

In the foreground you can see my 4:1 D300 and Klune. (it's split apart to clock the D300 flat)

[RescueJP]

way to make us all jealous DICK

[korisu56]

haha. no shit. you should see it in person, steve. i smile every time i see it, then cry inside.

[crazy4ink]

way to make us all jealous DICK

What did I do?? :D


To help give some scale, I have 24" from the bottom of my frame to the ground.

[xena warrior]

looks awsome definitly have to make the trip out to see this beast in person. joe

[crazy4ink]

looks awsome definitly have to make the trip out to see this beast in person. joe

Come on by!

[JavaTee]

In the foreground you can see my 4:1 D300 and Klune.

Which Klune model will be installed?
Later, T.J.

[friskeljr]

DAMN!!!!! Thats all I have to say about that

[crazy4ink]

Which Klune model will be installed?
Later, T.J.

it's the same Klune that I've been running for the last 2 years. It's the 2.72:1 version. That with my 4:1 d300, 7.02:1 first in my sm420 and my 5.13s give a final über-low of 399:1.

[crazy4ink]

haha. no shit. you should see it in person, steve. i smile every time i see it, then cry inside.

The last time you saw it, it was still on the old fullwidths and the 39.5s. It's actually 3"s lower than then.

[RescueJP]

stop braggin its talkin about a 399:1 crawl ratio makes me not be able to sleep at night.

[usnavymitchells]

Nice Rob. Is mine gonna look like yours when you are done???LOL

And who's that ugly guy with the funny hat.

[notarubicon]

Rob it is lookin good

[mousee]

And who's that ugly guy with the funny hat.

:D

[crazy4ink]

Well, Mousee and I have been working on the Jeep a lot trying to get ready for the Truck Nationals in a few weeks. We've gotten a lot done but there is still more to go. Most of the major stuff is done though.

I'll post more details later, but here are some more pics...

The new tranny shifter and triple stick setup. Yes they are all Craftsman.
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010183.jpg

http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010184.jpg

We decided to mount my amps up really high! :D
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010185.jpg

Here are the accessory brackets done and in paint. I'm actually using my OEM Power Steering Res on a PSC high-volume pump.
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010186.jpg

Dodge Powerwagon D60 is in, geared to 5.13 and converted from DRW setup to SRW setup. This pic is damn-near ride height with 42s to give some perspective!
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010187.jpg

D60 High Steer (this is the passenger side) with 1 3/4" DOM Tierod and Draglink setups that we built
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010188.jpg

Here's the driver's side
http://img.photobucket.com/albums/v494/crazy4ink/Jeep%20Surgery/P1010189.jpg

I'll snap and post some more pics later....

[JavaTee]

The new tranny shifter and triple stick setup. Yes they are all Craftsman.

Dodge Powerwagon D60 is in, geared to 5.13 and converted from DRW setup to SRW setup.

I like the shifters.

On the DRW/SRW. What is needed to convert the axle from one to the other? My friend is doing a Chevy D60, and is in the same situation you were in, except his is going under a '77 Cherokee Chief w/454-turbo 400, NP205 twin-sticked.

Thanks,

Later, T.J.

[crazy4ink]

A front D60 that is from a Dual Rear Wheel (DRW) truck, there are hubs that bolt to the brake rotor (about 8" wide per side) for 2 reasons. 1) Helps to even the trackwidth front to rear and 2) with the bolt-on adapter, you can use a single spare for the front and rear. DRW front D60 typically use external mount lock-outs. You can machine DRW hubs and use them in a SRW setup but it's not recommended (or safe) for highway use.

Read this link. There is a lot of info and the pics will help to explain things better.
http://www.pirate4x4.com/tech/billavista/60_front/index.html

If your buddy is using a kingpin D60, then Dodge and GM from '77-'89 are pretty much interchangable. I'll give you and example.
My front kingpin D60:
- 1979 Dodge Power Wagon (DRW originally)
- 1984 Chevy K30 SRW Calipers and Pads
- 1979 Dodge Power Wagon brake caliper mounts, spindles and spindle nuts
- 1984 Chevy K30 SRW rotors
- 1979 Dodge SRW hubs, inner and outer bearings and inner seal

It only gets tricky when you start trying to throw Ford kingpin D60s into the mix. Some parts interchange and some don't. Again, check the link I put earlier in the post. There is a TON of info and an interchange chart.

[JavaTee]

Thanks for the link.
Later, T.J.

[blackbetty]

AWESOME! hey rob how is that dash working out for ya? do you have any more pics of it installed?

[crazy4ink]

I have been really happy with the dash. I will get some more pics of it and get them on here.