Yet another diesel conversion project (YADC)

[budojeepr]

This should help with your glow plug wiring...

Thanks!

Whoa. I'm gonna need my readers...

[budojeepr]

Lockup wiring diagram

See http://www.ifsja.org/forums/vb/showp...5&postcount=9:

[budojeepr]

Got the new motor mounts from Novak today. They look exactly like what I need. They even sent a UPS ticket to send the old stuff back.

I'll try 'em out later (in the morning when it's not a zillion degrees in the garage - we hit 103 today), and as usual, post some pics and commentary.

[budojeepr]

Yet Another Test Fit - different mounts

The new motor mounts work much better.

Passenger side:


Driver side, before modification:


My modification to allow steering shaft clearance. Drilled a new hole 1-1/16" up from middle hole, cut off corner to clear:


The fit, after the mod:


Looks like it will work famously. I'm ready to tack-weld the mounts and check the fit. Then, burn them in. I think I'll move that gas can in the background before I strike a spark.

New issue: The transfer case clocked to work with the GM adapter hangs too low. The front drive shaft will hit the crossmember, and the transfer case is a rock-attractant. I'm going to investigate custom transmission/transfer case adapters...

(I got to do my bench-press practice today! An NP208 is a lot lighter than an NP205!)

[wickedwagon767]

Well well


what are you concocting here Bradford

Is this going into Leroy?

[wickedwagon767]

Howdy,

I thought I'd introduce my new diesel Wagoneer project.

Nevermind. I went back and actually READ the original post

[budojeepr]

Well well
what are you concocting here Bradford
Is this going into Leroy?

Welcome back, ww. Haven't seen you around these parts in quite a spell.

I thought this project would be a simpler one than the 454 for Leroy. HOWEVER, that is not the case. I'm (re-)learning the lesson that there is no such thing as a one-component swap.

Change the engine and transmission, and end up with new heads, injectors, glow plugs, intake and exhaust manifolds, switching to turbo, transmission shift kit, new torque converter, rebuild the transfer case, modify crossmember, upgrade front suspension, new exhaust, probably will modify drive shafts, new shifter, different heater core/fan, cooling system. Fancy-pants digital gauges. Oh, and re-gear the front axle and put in a locker while I'm at it. Woosh.

And I found out last week that CA DMV lost the Wyoming title and wants me to get a duplicate before I can renew the registration. I already did that once... Anybody heard from user "Brad W" lately (rhetorical - I'll do a search)?

I won't have to worry about the high cost of diesel fuel. I'll be smack out of cash by the time the Jeep's ready to drive!

[DieselSJ]

New issue: The transfer case clocked to work with the GM adapter hangs too low. The front drive shaft will hit the crossmember, and the transfer case is a rock-attractant. I'm going to investigate custom transmission/transfer case adapters...

(I got to do my bench-press practice today! An NP208 is a lot lighter than an NP205!)

Are you missing something? Like maybe your rubber mount? Doesn't it go between the crossmember and the adapter? That will raise the tcase a couple inches.

[budojeepr]

Are you missing something? Like maybe your rubber mount? Doesn't it go between the crossmember and the adapter? That will raise the tcase a couple inches.

Good eye, nice catch. The GM adapter is already a couple inches taller than the Jeep one. I was already planning to drop it via a crossmember mod so that the rear output would be in the original location.

It's the clocking that did it. It rotated perhaps 15 degrees CW (from the front) which dropped the front output quite a bit. I can design the crossmember modification around the front output, but it's still going to put that transfer case in harm's way. A nice custom adapter (like this one from Novak - $485.50! ) would solve all these issues; I just don't have the technology myself to create one.

[DieselSJ]

Good eye, nice catch. The GM adapter is already a couple inches taller than the Jeep one. I was already planning to drop it via a crossmember mod so that the rear output would be in the original location.

It's the clocking that did it. It rotated perhaps 15 degrees CW (from the front) which dropped the front output quite a bit. I can design the crossmember modification around the front output, but it's still going to put that transfer case in harm's way. A nice custom adapter (like this one from Novak - $485.50! ) would solve all these issues; I just don't have the technology myself to create one.

How about running a clocking ring? MUCH cheaper than an adapter.

[wickedwagon767]

I thought this project would be a simpler one than the 454 for Leroy. HOWEVER, that is not the case. I'm (re-)learning the lesson that there is no such thing as a one-component swap.

Anybody heard from user "Brad W" lately (rhetorical - I'll do a search)?

I won't have to worry about the high cost of diesel fuel. I'll be smack out of cash by the time the Jeep's ready to drive!

I'm running into some of my own potholes! Absolutely right. No sucha thing as a one-component swap. I'm swapping Dana60's under Sinjin with 38's. The Quadratrac won't survive...which means T-case swap and driveshafts......oh,wait, forgot the D60 front swap means I get to/have to run crossover steering too.......more power,cooling,cage,bumpers.......bank loan!

you can only hope to retain some sanity by laughing at yourself



Brad W just posted within the last day. Just don't remember where I saw him post

[budojeepr]

How about running a clocking ring? MUCH cheaper than an adapter.

Never heard of such a thing. Got a vendor? How would it work? Would the thickness of the ring affect the strength of the shaft/spline/input gear joint? Would that also affect the drive shaft lengths? The way it's working out now, even with the Novak adapter, I won't have to change the drive shafts at all.

Moot point...I've already ordered an adapter, sans shaft, from Novak.

Here are some pics from last night's welding of engine mounts, and the suspension with the engine weight on (I know, a lot of stuff is still missing that would add a lot of weight). A nice stroke of luck - one of the holes for the welds in the Novak mounts on each side works for the shock mounts. How cool is that?

Also, the front axle/suspension/steering is still WAY dirty. That whole assembly is coming out so I can do spring work and gearing, once I have the engine/trans swap stuff worked out. Then it's clean and paint time!

[DieselSJ]

A clocking ring is just a 3/4" thick ring that bolts between the trans and transfer case. It has multiple patterns so it lets you clock the tcase in 5 or 6 different positions. Advance has them, and I would imagine that Novak has them also. IIRC they were about $100 or so.

[budojeepr]

The Novak adapter came in yesterday. Seriously nice piece of casting/machine work. I'll have some time this weekend to put it in and get the crossmember all set.

Then we're off doing details. Feels like it's coming together!

[budojeepr]

Main tasks are done

Got the transfer case mounted up with the Novak adapter today. The foot they supplied bolted right to the same holes the old one used. It's all in the same location; the drive shafts should not need any modifications save new u-joints.





My assistant, Rock Star. Not good at swapping tools or fetching the occasional beverage, but he has a great can-do attitude.