LS Swap Transmission/Transfer Case options for 68 Wagoneer

[Rellim51]

I'm getting ready to do some major upgrades to my newly acquired 1968 Wagoneer and I need some advice.

My plans:

I want to build a good driver. I'm at least 1.5hrs away from any decent trails/backcountry camping so this will be more of a driver than a wheeler. I want to leave the exterior just as it is and upgrade the drivetrain. I'm planning on a 4" lift and running 33x10.50 tires. I'm swapping in a 2005 5.3ls engine and I'd like to use a 4l60E overdrive if possible. I bought a 78 Wagoneer for parts and I plan on using the axles to gain power disc brakes and power/tilt steering.


Info on my Jeep:
1968 Wagoneer
Bone Stock
232/3-speed manual
Dana 20 transfer case
Dana 27? and Dana 44 (tapered shafts)
4.10 gears






My parts Jeeps:
1978 Wagoneer
Bone Stock
360/TH400
Quadra Trac (with low range)
Dana 44's
3.07 gears

70ish J4000
Buick style TH400/dana 20

Engine swap parts:
2005 Chevrolet 5.3/4L60-E (2wd)


I have quickly figured out that an LS swap is no where near cheap or easy in one of these Jeeps. The engine swap its self doesn't bother me, its the transmission/transfer case/axles that have me stumped.

I'm planning on putting the 78 QT axles in my 68 to gain power disc brakes and a better rear Dana 44.

So far, I've come up with these options:

TH400/QT -
will need to convert to a chevy case/rebuild and adapt to LS engine
QT I have will probably need a rebuild
may not need new driveshafts

700R4/QT-
will need to buy a 4wd 700R4 and adapt to LS engine
will need 700R4 to QT adapter
QT I havewill probably need a rebuild
will need to adapt TV cable to my drive by wire engine
will need torque converter lock up controller
will need new driveshafts

4L60E/QT-
will need to convert my 2wd trans to 4wd
will need adapter to convert 6 bolt housing to 4 bolt(700R4 style)
will need 700R4 to QT adapter
QT I have will probably need a rebuild
Will need to re gear axles
will need new driveshafts

4L60E/Dana 20
will need to convert my 2wd trans to 4wd
will need transfer case adapter
may have D20 to QT rear axle angle issues
will need D20 output shaft/housing upgrade
will need to re gear axles
will need new driveshafts

TH400/Dana 20
will need to convert to a chevy case/rebuild and adapt to LS engine
may have D20 to QT rear axle angle issues
will need D20 output shaft/housing upgrade
may have D20 to QT rear axle angle issues
will need new driveshafts

4L60E/NP241-c
will need to find/buy NP241
will need to re clock transfer case
will need slip yoke eliminator eliminator
may have NP241 to QT rear axle angle issues
will need to re gear axles
will need new driveshafts

As you can see there's no easy or cheap combination. I'd really like to use the electronic 4L60E transmission if possible but it pretty much adds another $1500+ to the cost of the build plus I will have to re gear both axles. Are there any other combinations I'm missing with the parts I have? What's the best/cheapest combination with what I have to work with?

[babywag]

Personally I would not use a QT. Definitely would not buy $$$ adapters to use one.

I'd look @ grabbing an '80-up donor SJ for axles or just front axle.
Driver drop front axle and more centered rear axle.

[Rellim51]

Parts jeeps are extremely hard to find in my area so I'd like to use the parts I have if possible.

[babywag]

Using what you have doesn't always make the most financial sense.

A 2wd trans. is going to cost you a lot more than starting with a 4wd.
Output shaft change and TC adapters are gonna be a $$$ leech.

[chrism]

My opinion...start selling parts...below is the best option for a 5.3 swap.

4L60E/NP241-c
will need to find/buy NP241
Easy to find for driver drop front axle (little harder for passenger drop since they were only used for 3 years in the blazers and suburbans. You could also use a np208 if you had to)

will need to re clock transfer case
Maybe not if you go with driver drop front. Definately on passenger drop front and stock crossmember.

will need slip yoke eliminator eliminator
Both my FJS's with 241's did not need this. Is nice to have though.

may have NP241 to QT rear axle angle issues
Possibly ok depending on who you talk to. I'm going 14 bolt in the rear for my current build.

will need to re gear axles
Definately if your using the 3.07 axles

will need new driveshafts
Yep...I did find that the front driveshaft from the 89 blazer I got my 241 from fit perfectly but it still needs rebuilt.

One other thing to think about is changing to a rear mounted gas tank. I am using the S10 blazer tank between the rear frame rails. Already set up for EFI and frees a lot of room up under the jeep.

[yossarian19]

Wait, you need to clock the 241-C for a passenger drop axle? I hadn't run into this yet... any more info?

[Rellim51]

I don't think you have to clock it but it makes fitting the transmission crossmember a lot easier.

[babywag]

If you look @ any SJ w/ TH400 the transmission is clocked some for front driveshaft clearance.

If trans. or transfer case is not clocked very probable you'll have clearance issues with front driveshaft?

However lots of variables...
A swap may alleviate the need or it could make it mandatory.
Lifted? Engine location? Transmission length? transfer case used? etc. etc. etc.

[chrism]

Wait, you need to clock the 241-C for a passenger drop axle? I hadn't run into this yet... any more info?

Yep. If you are using the stock cross member (for a 79 at least) the front output would need to go through the cross member without clocking. If you mock the whole drivetrain up on the floor with the cross member attached to the tcase you will see. You could modify the cross member if you wanted but I felt like the 241 hung down too low. If you look at the chevy cross member there is a big dip on that side to accommodate it in the suburban or blazer the 241 likely came from.

I bought a clocking ring off ebay for like $45. Up one bolt hole will clear. I put mine up 2 but had to clearance a heat shield on the underside of the body with the jeep hammer. I may end up moving it back down a notch so I have more room to run exhaust down that side though.

[ProTouring442]

Adapting the 2wd trans to 4wd is not difficult. If you can rebuild an engine, you can replace the output shaft.

[rang-a-stang]

that patina is SOOoooo spot one! I LOVE it! I am soo glad you wrote "I want to leave the exterior just as it is"

In fact, if I had bottomless pockets and your rig, I would have the rims widened to fit the tires you want but keep the hubcaps.

Sorry, I got nothing for your swap question. My truck is bone stock and I am still fairly new to FSJ so all you get from me is some affirmation on your choice of exterior décor.

[ProTouring442]

In fact, if I had bottomless pockets and your rig, I would have the rims widened to fit the tires you want but keep the hubcaps.

I'm sure one of the steel wheel manufacturers make a wheel that would allow for the stock hubcaps while being a wider or even larger in diameter rim.