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  #1  
Old 09-05-2010, 09:03 PM
WillysDriver WillysDriver is offline
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Grand Wagoneer / Cummins 4BTA swap

Well I got the Cummins 4BT swap done in the family hauler just in time for my wife to have our baby boy. The Family Hauler made the debute on Monday and the baby was born on Wednesday...2 weeks early! I'm glad it's done as Jeep wrenching time will be at a premium for some time now.
Here's a bit of info:
-Reman Cummins 4BT with a new Bosch VE pump and Injectors setup for 120HP, Water/Air charge air cooler
-'91 Dodge Ram 3 Speed TF727 mated to original NP229 T-case Custom shafts
I'll try to get some on road/ in use video when I get a chance..

http://www.youtube.com/watch?v=mFVfGD4NsfY
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  #2  
Old 09-05-2010, 09:27 PM
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BGW BGW is offline
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Very nice! I love how you kept the 229 t case. Great looking rig!
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  #3  
Old 09-05-2010, 09:30 PM
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WagoneerinWi WagoneerinWi is offline
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Awesome, looks and sounds great. Congrats on the new baby. I have a 2 year old and a 1 year old (both girls). Nap time is about it for wrenching.
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  #4  
Old 09-05-2010, 11:11 PM
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Tigger4X Tigger4X is offline
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Sweeet! SUBSCRIBED to see more with your updates. I'd love to hear about any hiccups and especially about your MPGs with the mods you made.

CONGRATS on your future jeeper! A baby boy ...
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Post #14 ~ http://www.ifsja.org/forums/vb/showt...=1#post1580206
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  #5  
Old 09-06-2010, 12:21 AM
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Wayne Wayne is offline
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Sounds and looks good, nice work there.
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  #6  
Old 09-06-2010, 12:51 AM
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mdill mdill is offline
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Very cool, looks like a nice job on the swap.
We need more details on the setup, accessory set up AC , power steering ? , still has vacumn power brakes, vacumn pump ?

Very sweet, please exapnd on the issues you had and solutions.

Thanks Mike D.
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  #7  
Old 09-06-2010, 06:08 AM
Greenfish Greenfish is offline
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Thats really cool, and got me thinking
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  #8  
Old 09-06-2010, 06:29 AM
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COLOFIREMAN COLOFIREMAN is offline
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OK OK, I just need to finish mine now!!!!
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  #9  
Old 09-06-2010, 06:44 AM
rocklaurence rocklaurence is offline
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Very NICE! How did you manage to keep the heater box and power brakes? I seems like you made it fit while the others couldnt.
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  #10  
Old 09-06-2010, 08:35 AM
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Brizio Brizio is offline
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Nice Job!
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  #11  
Old 09-06-2010, 09:52 AM
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The PIG Smith The PIG Smith is offline
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Quote:
Originally Posted by mdill
Very cool, looks like a nice job on the swap.
We need more details on the setup, accessory set up AC , power steering ? , still has vacumn power brakes, vacumn pump ?

Very sweet, please expand on the issues you had and the solutions.

Thanks Mike D.
X2!
Excellent work!

What color red did you paint the engine? Chevy Orange? IH Red?

Also, I noticed that your 4BT sits really far back in the engine bay.
I assume you did that to because you worked from the transmission forward

Did you have any issues with the height of the 4BT?
Did you need to use a body lift or suspension lift?

Does the turbo interfere with the heater box?
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  #12  
Old 09-06-2010, 11:26 AM
WillysDriver WillysDriver is offline
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The engine is painted IH red, good eye. The Jeep was lifted with 33" BFG ATs by the previous owner, so I'm not 100% on make of lift or exact height. The engine was positioned for optimal oil pan clearance and hood clearance. The factory heater box is in the original position as well as the factory Vacuum booster. A '94 Dodge 5.9L vacuum pump and PS pump are used to supply the Jeep units. A 90 Degree Corvette style speedometer drive was installed to run the factory speedometer. This was due to the driveline positioning and fuel tank position. Custom crossmember fabricated and transmission mounting. The original rad has been reused using a stainless steel crossover pipe. At this time there is no engine fan, but that will be added once I get the AC hoses crimped and installed. The 3.9 Doesn't have the giddy-up like my 5.9 L Cummins powered '82 Cherokee, but it will be great for moving my family around in style.

Here's some pictures...more to follow
http://

Last edited by WillysDriver : 09-06-2010 at 01:12 PM.
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  #13  
Old 09-06-2010, 01:27 PM
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Tigger4X Tigger4X is offline
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No mention of the turbo unit and I'm not seeing an intercooler. Maybe the Rx on my spectacles need to be refilled.

It looks like its plumbed from the top over to the passenger side and down, but its outta view. You originally posted about a "Water/Air charge air cooler". Where is mounted and where did you plumb it?


Did you do any documentation with pics during the upgrade process? Or have any further specifics on the build? I'm getting ready to build up a quad-cab J-truck with a diesel and am just getting into the dark smokey side of life. There are a few diesel conversions on here with minor differences on the install and fitment. Do you have any real world numbers on MPGs with the 4BT? I'm most likely to go with the 4BT, but havent completely ruled out the 6BT; just wanting to figure the last details as to which would serve me best in real world application. I'm not out for monster power, but dont want to be miserable with a dogged down engine. Mostly MPGs are the primary concern while hoping I can pull something decent behind me when needed. Hearing that you have a 4BT and a 6BT has me chomping at the bit to get your input! Your build looks solid and like its supposed to be there which is what I'm after looks wise. GREAT JOB!!









Great Googley Moogley that filter is tooooouuuchy! I had to fill in spectacles instead of g l a s s e s cuz it bungled it into glGreat Googley MoogleyGreat Googley MoogleyGreat Googley MoogleyGreat Googley MoogleyGreat Googley Moogley. SHEEESH
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Quote:
Originally Posted by will e
Keep in mind. Getting old is easy. Being old is hard.
Post #14 ~ http://www.ifsja.org/forums/vb/showt...=1#post1580206

Last edited by Tigger4X : 09-06-2010 at 01:43 PM.
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  #14  
Old 09-06-2010, 04:18 PM
WillysDriver WillysDriver is offline
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The housing that the turbo crossover pipe goes to is a Water/Air aftercooler. Inside is basically a small radiator. The compressed air is cooled (Not as much as an air to air obviously) before entering the intake. When I did the Chief 5.9L swap I had to relocate the battery and modify hood catch to fit in the Gen 1 Dodge intercooler. I decided this time that I'd go this direction. The 4bt can be juiced up but for now it works fine for this application. If you plan on doing a pile of towing or work with the truck. I would probably go with the 5.9L. My Chief works great and has towed my V2003 Kubota powered '47 Willys all over the place, as well as been a daily driver. I notice the lack in power in the 4bt, because like you said...I have both. I'll let you know more about the MPG when I get a few tanks of fuel through it. From the two tanks I've burned it's around 24 MPG with the 4BT/3spd/2.73 axle/33" BFG AT. Oddly enough...the Chief gets close to that if you don't lean into it all the time. It has a 5.9/3spd/3.31 axle/ 35" Mudkings.

Last edited by WillysDriver : 09-06-2010 at 04:25 PM.
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  #15  
Old 09-06-2010, 04:25 PM
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mdill mdill is offline
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He is running a air-water intercooler, standard Cummins on the intake side, you can see the plumbing, I was wondering about the pumbing, I am guessing engine -> Heater core -> intercooler -> water pump, but like you say hard to see the hose routing.

Looks like it fits well, I like that is is further back, that should help alot in keeping it from being nose heavy, should have pretty good ballance with it stuffed back there.
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Home of ADHD project list

1977 J-10 Honcho 360-T15-D20
1977 Cherokee WT 360-Th400-NP241 true-trac(s)
1979 Cherokee 4 Door 258-T-18-D20
1981 Cherokee Chief WT 360-727-NP208
1972 K20 Suburban 350 SM465 205
And the other stuff that gets driven
----------------------------------------
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  #16  
Old 09-06-2010, 05:08 PM
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Tigger4X Tigger4X is offline
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Quote:
Originally Posted by WillysDriver
The housing that the turbo crossover pipe goes to is a Water/Air aftercooler. Inside is basically a small radiator. The compressed air is cooled (Not as much as an air to air obviously) before entering the intake. When I did the Chief 5.9L swap I had to relocate the battery and modify hood catch to fit in the Gen 1 Dodge intercooler. I decided this time that I'd go this direction. The 4bt can be juiced up but for now it works fine for this application. If you plan on doing a pile of towing or work with the truck. I would probably go with the 5.9L. My Chief works great and has towed my V2003 Kubota powered '47 Willys all over the place, as well as been a daily driver. I notice the lack in power in the 4bt, because like you said...I have both. I'll let you know more about the MPG when I get a few tanks of fuel through it. From the two tanks I've burned it's around 24 MPG with the 4BT/3spd/2.73 axle/33" BFG AT. Oddly enough...the Chief gets close to that if you don't lean into it all the time. It has a 5.9/3spd/3.31 axle/ 35" Mudkings.


The 3spd transmissions you have, are they auto or manual? I have been considering a TH475 and the NV4500.

I havent nailed down the gear ratio yet but would like to do what I can to maximize MPGs and can always incorporate something like a Doubler t-case to get and enhance the off-road capability. I also havent nailed down the tire size. I would expect to be somewhere around 35-36".

Is the housing you speak of on top of the engine? Or is it down below out of sight?

Is the 5.9L back as far as the 3.9L seen in your pics?

In either case did you have to modify the firewall sheet metal to get them to fit that far back?

And do you happen to have any pics?

Considering the advantages of the air to air intercooler what do you think of this pic of the intercooler being mounted in front of the stock coolant radiator?



The blue hose you see runs to each side and then does a 90* back thru the front sheetmetal and then is routed appropriately.

I have heard of using cerami-coating to keep the heat in where it belongs and out of components that need the cool to maximize efficiencies. Do you know of any tips to enhance the effectiveness on the smokey side of things?
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Quote:
Originally Posted by will e
Keep in mind. Getting old is easy. Being old is hard.
Post #14 ~ http://www.ifsja.org/forums/vb/showt...=1#post1580206

Last edited by Tigger4X : 09-06-2010 at 05:12 PM.
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  #17  
Old 09-06-2010, 06:26 PM
WillysDriver WillysDriver is offline
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Digging deep for this thread...if you check out the Chief Build, you can see where I put the Dodge intercooler in:
http://www.ifsja.org/forums/vb/showt...t=willysdriver

The aftercooler is the unit directly beside the valve covers, that the turbo crossover tube attaches to. If you click on the Waggy icon higher up in the thread you can see the pictures I've loaded so far.
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  #18  
Old 09-06-2010, 06:49 PM
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Tigger4X Tigger4X is offline
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Thanks for the reminder to check the waggie thumbnail. Some good looking stuff for sure.

I went back and reread and answered a couple of my own questions such as auto or manual trans and the turbo.

What did you think of the intercooler pic I posted?

When you get a chance would you also check my previous post and update me when you can. Thanks!
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Keep in mind. Getting old is easy. Being old is hard.
Post #14 ~ http://www.ifsja.org/forums/vb/showt...=1#post1580206
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  #19  
Old 09-07-2010, 04:35 PM
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M4203 M4203 is offline
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Congrats on your son, would love to do a 4bt swap also.
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