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  #41  
Old 03-25-2009, 12:22 PM
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JeepinPete JeepinPete is offline
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Monday night I pulled the tranny and transfer case off of the 5.3L. One of the issues I've been worried about is clearance for the clutch slave cylinder. On this particular transmission, the slave is external, and mounts to the bell housing. I hate internal slave cylinders with a passion (hydraulics will leak eventually, pulling the drivetrain to replace a slave cylinder is not my idea of a good design).

Anyway, I bolted the adapter plate to the trans Monday night, and marked out where I would need to cut to clear the slave cylinder. Brought it to work yesterday and cut it on the bandsaw. Last night's test fit showed I hadn't removed enough material, so a little work with a sanding drum and file took care of that. Then came the moment of truth, would the Isuzu clutch housing clear?







I had to file the lip of the clutch housing so that I could remove the slave cylinder in the future. I will have to grind a divit in the side to fully clear the bleeder. But it fits

Some other minor issues have shown up. Both of the crank spacers need a little tweaking. One hole on the steel spacer drifted when I drilled it. I will have to run an endmill from the backside to fix that. On the aluminum spacer, two of the clearance counterbores are slightly off. Just enough to prevent it from seating on top of the steel spacer with the bolts in place.

I am trying to order valves and a head gasket, but the source I found is not exactly speedy. I am waiting for an invoice so that I can pay them for the parts, but nothing has shown yet. I hope to have them in hand next week.

With any luck, I will stab the drivetrain back into place next weekend
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'55 Willys Wagon, the original FSJ
Sitting on a '77 Cherokee frame, Dodge D60's
Isuzu 6BD1, NV4500, NP241
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  #42  
Old 03-26-2009, 09:38 AM
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Got a good amount of time out in the barn last night. Started putting the drivetrain together. I'll have to pull it all apart again, since I have a new flywheel on the way. I also need to adjust the size of the dowel pins that locate the trans. They ended up oversized. But next time should be the last time

Here is the divot I had to grind to clear the bleed screw. I also ended up grinding off the nipple on the bleed screw...



The following pictures are just a progression of how it goes together...















All told, the drivetrain measures 7 feet long from the crank pulley to the output yoke.
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'55 Willys Wagon, the original FSJ
Sitting on a '77 Cherokee frame, Dodge D60's
Isuzu 6BD1, NV4500, NP241
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  #43  
Old 03-26-2009, 12:22 PM
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That's pretty bad when your front driveshaft is going to be longer than your rear one.

Pete, I get first dibs on this setup a year from now when you swap it all out for batteries and electric motors. Looks awesome.



JR
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  #44  
Old 03-26-2009, 12:39 PM
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LMAO, I'll keep that in mind JR...
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'55 Willys Wagon, the original FSJ
Sitting on a '77 Cherokee frame, Dodge D60's
Isuzu 6BD1, NV4500, NP241
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  #45  
Old 03-26-2009, 05:46 PM
mjself mjself is offline
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Pete, you are one heck of an artist. Very impressive!
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  #46  
Old 03-27-2009, 08:53 AM
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Thanks, but I definitely am no artist. I am a mechanical engineer, and this is my idea of a good time
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'55 Willys Wagon, the original FSJ
Sitting on a '77 Cherokee frame, Dodge D60's
Isuzu 6BD1, NV4500, NP241
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  #47  
Old 03-27-2009, 09:20 AM
GWChris GWChris is offline
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Nice work Pete, I like the drivetrain idea. That's an ambitious project but you're doing it very well. Wish I had the time to try something like that!

Perhaps I'll see that driving around soon - I live very close to Quakertown and go through all the time.
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  #48  
Old 03-30-2009, 01:54 PM
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I've been driving it around for the last year and a half. I do get a lot of looks

Not much of interest to report. I changed gears a bit with my flywheel choice. I am using a GM Vortec flywheel, '01 and newer, since Sachs is making an inexpensive part now. That will require me to remove .4" from the aluminum crank spacer. Not a big deal at all, since I was having interference issues with the M14 bolt heads. Looks like they are a bit thicker than McMaster stated in their drawing. That would also explain the crazy runout I was measuring.

So the drivetrain got put on hold for the weekend, and I concentrated on cleaning up the frame and firewall. All the normal fun stuff, wirewheeling, grinding, just making a huge mess. I welded up a bunch of holes in the firewall while I was at it, and painted everything with Rust Bullet.

Still planning on stabbing the drivetrain back into the Jeep this coming weekend...
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'55 Willys Wagon, the original FSJ
Sitting on a '77 Cherokee frame, Dodge D60's
Isuzu 6BD1, NV4500, NP241
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  #49  
Old 04-05-2009, 05:24 PM
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The drivetrain is sitting between the frame rails

My buddy Joe came by this morning, and we got the thing in place. Looks pretty good clearance wise. The turbo is pretty close to the brake MC, and the oil vapor separator is to close to the heater box, but that is the extent of my problems. I need to make up motor mounts, and modify the crossmember for the transmission mount. Anyway, enough talk. Here are the pictures...











Needless to say, I got the head and valves fixed up before it went in. The oil buildup in the intake ports was unreal. That was a messy job getting it cleaned up. I used a bit of valve lapping compound to seat the two new valves.



Last picture for the night. The drivetrain before it went in this morning. I left the doubler out for now, still need to weld up the output shaft.

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'55 Willys Wagon, the original FSJ
Sitting on a '77 Cherokee frame, Dodge D60's
Isuzu 6BD1, NV4500, NP241
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  #50  
Old 04-05-2009, 06:50 PM
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Checking in as an AMC "purist" here.... If you pull 28mpg outta this I'll be looking to re-gear my 455 dually and hit you up for design work to match my NV4500. I'd love to make a daily driver out of my tank.
Great work!

BTW, I'm guessing these are a lot smoother running/higher reving than the pup 2.2 back in the '80s? My buddy had one he was pulling 42-45mpg out of...
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Last edited by Elliott : 04-05-2009 at 06:53 PM.
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  #51  
Old 04-06-2009, 11:13 AM
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28 might be a stretch, but I am hoping for 25. I will know soon enough.

I am not familiar with the 2.2, but I doubt it is smoother. This thing has a near 4.5" stroke. Hard to be smooth swinging a lot of mass that far around.
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'55 Willys Wagon, the original FSJ
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Isuzu 6BD1, NV4500, NP241
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  #52  
Old 04-06-2009, 02:28 PM
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Well, the 2.2 would about rattle you out of the cab and you couldn't talk without shouting at 60 mph. The cabs were real thing though, kinda like riding in a slow popcorn popper, but the mileage was great and I was just starting to look around for one of those to maybe replace my Ranger.
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  #53  
Old 04-07-2009, 07:51 AM
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Designed up the motor mount bracket yesterday. I am using existing sleeved holes in the frame, and the motor mount bosses on the block. The mounts themselves are out of a Ford Escort of all things. They are big, beefy, and have a lot of rubber to dampen vibration. Time will tell if this was a good idea or not



I finished up the engine side last night, tonight I will make up the frame side. Wed night I plan on doing the mods to the tranny cross member. So it should be hanging by tomorrow night

My exhaust isn't going to work out like I showed in previous models. It actually will be a lot easier. I picked up a set of Dodge Dana 60s for a song last week. The front axle happens to be a right hand drop axle. It just so happens that GM used both left hand and right hand drop NP241's over the years. Of course the one I had on hand I sold last month So the search is on. The right hand drop cases are not nearly as common as the left had drop versions. But by switching to the other side, the exhaust is now a straight down drop, and straight out to the back of the truck.
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'55 Willys Wagon, the original FSJ
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Isuzu 6BD1, NV4500, NP241
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  #54  
Old 04-07-2009, 07:54 AM
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Your wife still let you in the garage after you told her you bought that lathe?

All jokes aside, that looks awesome. Hopefully you have it done when we meet up, I'd love to see it.
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  #55  
Old 04-07-2009, 08:15 AM
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25 is well within reason. i was pulling down 21 with mine turned WAY up and soot billowing out. now with things cleaned up i burned 7 gallons in 182 miles. hard to gauge as totally accurate but i was pretty excited considering i was used to watching the gauge move on its own with the 401. anything over 10 was always earth shatering...... It's still a flying brick
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The 608.9 hybrid dana 44 build

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  #56  
Old 04-07-2009, 09:22 AM
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Lathe? What lathe

I plan on staying on the lean side of things. I really do not like diesel smoke. The one thing I really likes about my TDI Jetta was how little is smelled once it warmed up a bit. I am hoping the Isuzu can be tuned to run pretty clean with the HY35 turbo. Time will tell I guess.
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'55 Willys Wagon, the original FSJ
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Isuzu 6BD1, NV4500, NP241
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  #57  
Old 04-07-2009, 09:27 AM
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the compressor on the hy is still bigger than stock so it will take a little more heat and gasses to get it to spin than what the stocker took but the real benefit si the small exhaust housing aids in overcoming that. mine spools instantly and other than a small puff off the line the motor is supprizingly clean.


No worries that thing will be clean as soon as you start it up. keep from fiddling with the lower smook and low boost settings and just focus mainly on the full power settings and you should have really good performance with minimal bottom end smoke if any.


Govenor spring kit is Key though
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Cherokee S Chief Widetrack W/ Cummins 4bta Diesel, 91 dodge intercooler, hy35/9, AC NV4500/D300 3.54's Ploks 4" BJ's w/ 33's, scout 33 gal fuel tank ( Sold, to a good fsj home)
The 608.9 hybrid dana 44 build

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GO UM Montana Griz

"Dont worry the Coors light engineering department will be documenting this accordingly."
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  #58  
Old 04-07-2009, 09:35 AM
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Quote:
Originally Posted by JeepinPete
Thanks, but I definitely am no artist. I am a mechanical engineer, and this is my idea of a good time

Great work! I´m a mechanical engineer too. I have unusual hobbies that involve black smoke too

Keep us updated!
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  #59  
Old 04-07-2009, 09:40 AM
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The "A" pump on the Isuzu doesn't seem to have the variety of adjustments that the Cummins pumps have. From what I have read, it is pretty much just the max fuel adjustment on these pumps. And there is no need for a different governor spring, these things red line at 3600rpm from the factory.
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'55 Willys Wagon, the original FSJ
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Isuzu 6BD1, NV4500, NP241
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  #60  
Old 04-07-2009, 09:40 AM
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Quote:
Originally Posted by dusty
25 is well within reason. i was pulling down 21 with mine turned WAY up and soot billowing out. now with things cleaned up i burned 7 gallons in 182 miles. hard to gauge as totally accurate but i was pretty excited considering i was used to watching the gauge move on its own with the 401. anything over 10 was always earth shatering...... It's still a flying brick

My 4BT-powered J300 gets about 23MPG doing 80MPH on the highway. Which is a vast improvement over the 11MPG I used to get with the gasoline engine... Doing 60.


Quakertown PA? We´ll have to organize a FSJ gathering some time. Poolmike (M715 with a 4BT) is not far from you...
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Last edited by Mikel : 04-07-2009 at 09:42 AM.
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