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EMTimZJ
09-12-2006, 06:53 PM
Build up thread of “Project Tortoise”
-Some of these pictures may be out of chronological order, but hopefully you get the picture!


Stock: 1994 ZJ LTD 5.2L / 46RH / NP249


I purchased this ZJ after I struck two white tail deer @ 55 MPH simultaneously. Needless to say the 1997 Plymouth Breeze took it like a champ except for the bumper, headlights, grill, hood, quarter panel, windshield and air-bag… ok it was totaled.

I get the rig and basically have no clue what I am doing. I purchased some weird “mods” and put them on… boy was I nothing but :bling:

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/IMG_6479.jpg

Yikes.

Soon after that I did some research and started off in the right direction. Kolak helped me get all the right parts.

RE 3.5” SR-adjustable lowers, JKS TB’s front and rear with Kevin’s TB conversion, RE’s bling brake line extension, Tera-flex bump stops, JKS gen II disco’s, OME SD-40 and DT3000’s

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/DigiPictures002.jpg

Stock swaybar studs meeting the cut-off wheel:

http://www.jeepforum.com/gallery/files//4/8/0/6/7/DigiPictures006.jpg

Put on some JCR sliders and Kumho 31x11.5’s and a used ARB in the D35 and finally did some real wheeling at Paragon.

http://www.jeepforum.com/gallery/files//4/8/0/6/7/DigiPictures153.jpg

EMTimZJ
09-12-2006, 06:53 PM
Spring of 2005 my fuel pump died. Fixed with the Swampy Bypass, Thanks Carl! (aka Swamp Boy)

http://www.jeepforum.com/gallery/files//4/8/0/6/7/DigiPictures030.jpg

http://www.jeepforum.com/gallery/files//4/8/0/6/7/DigiPictures036.jpg

http://www.jeepforum.com/gallery/files//4/8/0/6/7/DigiPictures034.jpg

http://www.jeepforum.com/gallery/files//4/8/0/6/7/DigiPictures035.jpg

Tweedy mat was on sale for $0.49!


By the time of my next run to Paragon, the light-bar was removed along with the bumper fascia.

http://i16.photobucket.com/albums/b11/EMTimZJ1/Paragon%20Run%20II/ParagonII083.jpg

Wheeled again at Badlands in October of 2005… bumper cover just zip-tied on in case IN cops feel like giving me a hard time. MI cops could care less.

http://i32.photobucket.com/albums/d22/blaine59/IMG_8868.jpg

Scored an entire HP30 from a 96 XJ for $40

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/DigiPictures010.jpg

All polished with an ARB and just waiting for steering links to finish the WJ knuckle swap

(yikes what a horrible picture!)
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans011.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans015.jpg

Stock 1995 Crown Victoria rotors work with no machining or redrilling the bolt pattern.
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans016.jpg

CO2 tank from www.ultimate-air.com (http://www.ultimate-air.com/) This guy is somewhat local and gave me a killer deal on this 15lbs system. Basically only $30 more than assembling my own but the mounting bracket was included.

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/DigiPictures078.jpg

EMTimZJ
09-12-2006, 07:00 PM
Anyone want to guess what fluid this is?


http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/uhoh004.jpg

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/uhoh005.jpg

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/uhoh006.jpg

Tranny fluid that is only 7,000 miles old.

Filter shot after I dropped the pan:

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/46RH001.jpg

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/46RH002.jpg

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/46RH003.jpg

Basically, my cooler lines running to the front leaked and pissed half my tranny fluid out on I-96 while I was driving. Trans overheated from running WAY low on fluid and well, this is the result along with internal damage. So much fun!:cheer2:

EMTimZJ
09-12-2006, 07:13 PM
I fixed the leaking plenum gasket and did a little write up about it here:
http://www.jeepforum.com/forum/showthread.php?t=233448
http://i16.photobucket.com/albums/b11/EMTimZJ1/Plenum%20Gasket/PlenumGasketFix001.jpg

I also installed the Taurus E-fan at the same time:
http://www.jeepforum.com/forum/showthread.php?t=233676
http://i16.photobucket.com/albums/b11/EMTimZJ1/E-Fan%20Install/E-FanInstall008.jpg
I rebuilt and swapped in an NP242:
http://www.jeepforum.com/forum/showthread.php?t=239528
http://i16.photobucket.com/albums/b11/EMTimZJ1/TransfercaseSwap/DigiPictures005.jpg

EMTimZJ
09-12-2006, 07:35 PM
Before my tranny died I had started the build up of a Toyota 8" rear axle.

Pulled a Toy 8 from a 93 4runner at the bone yard for $50.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/GSMW-May2006BadlandsIN013.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/GSMW-May2006BadlandsIN014.jpg

Cleaned up, drilled, tapped, and clearanced to accept the Toy E-locker:
More info on this process here: http://home.off-road.com/~kemanuel/elocker/elocker.html (http://home.off-road.com/%7Ekemanuel/elocker/elocker.html)

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/JeepTrans019.jpg

Having fun cutting:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-42006012.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-42006011.jpg

Welding the perches and brackets:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/July52006019.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-42006010.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-42006022.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-42006017.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-42006006.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/toyeightinch002.jpg

I can't believe I forgot to take a before picture, but Toy 8's have a drain plug on the bottom that hangs kind of low. I welded it up and cut/ground it flat and smooth. I also smoothed out the transition of the weld on cover I bought from www.sky-manufacturing.com

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/toyeightinch001.jpg

Cleaned out and ready to get prepped for paint:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/toyeightinch004.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/toyeightinch005.jpg

New studs on ice from the freezer, axle flange getting the torch. This makes it easier to drive in those studs.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/toyeightinch006.jpg

Toy e-locker
http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/namethatdiff01.jpg

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/namethatdiff02.jpg

DJJordache
09-12-2006, 08:35 PM
nice journal! I need to make one of these doohicky's... anyways that is Claytons high-clearance bracket kit right? It kind of "re-index's" the control arm mounts up higher to be able to move the lowers up right? looks great so far!

EMTimZJ
09-12-2006, 09:09 PM
nice journal! I need to make one of these doohicky's... anyways that is Claytons high-clearance bracket kit right? It kind of "re-index's" the control arm mounts up higher to be able to move the lowers up right? looks great so far!

Nope, axle brackets were some my home-brew design that I traced out and had a buddy cut for me. :smt112

EMTimZJ
09-12-2006, 09:14 PM
Wheels, knuckles, caliper brackets getting primered.
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans003.jpg

Wrenching came to an abrupt stop when I found this male Io moth (Automeris io) underneath the ZJ. Being the complete science dork I am, within 3 minutes it was identified in my Audubon book and I was scrolling through info on the 'net. Pretty cool huh?
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans014.jpg
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans012.jpg


Mini-van for designated tire pickup duty.
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans007.jpg

Yep they'll fit! (hey it is a grand!.....caravan!)
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans008.jpg

EMTimZJ
09-12-2006, 09:32 PM
Sitting pretty on the jackstands; transmission, tcase, front and rear axle removed:
http://i79.photobucket.com/albums/j128/EMTimZJ11/AronBike018.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/AronBike020.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/AronBike019.jpg

Shot of the back of the 318 block:
http://i79.photobucket.com/albums/j128/EMTimZJ11/freezeplugs-1.jpg

Looking up through the floor:
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans006.jpg

Here I am actually sitting up on the garage floor under the ZJ. I was attaching the Crankshaft Position Sensor to the rear of the block.

http://i79.photobucket.com/albums/j128/EMTimZJ11/August152006PoolPics003.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/August152006PoolPics004.jpg

Since the auto trans was fried to a crisp, I started to get creative with the drivetrain plans.

An NP435 manual transmission, to a home-brew 249 reduction box to a EB Dana 20 tcase:

249 reduction box back from the machine shop. (not 100% complete. I still needed to hack part of that shift rail off and weld on a small cap.
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans017.jpg

NP435 + 249 reduction box.
http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans023.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/JeepTrans022.jpg

EMTimZJ
09-12-2006, 09:39 PM
EB Dana 20 from the junk yard:
http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/Picture003.jpg

http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/Picture001.jpg

Modified for twin stick operation:
Write up is here: http://www.mallcrawlin.com/forum/showthread.php?p=91581#post91581

http://i79.photobucket.com/albums/j128/EMTimZJ11/Dana%2020%20Twin%20Stick/Dana20TwinStick001.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Dana%2020%20Twin%20Stick/Dana20TwinStick004.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Dana%2020%20Twin%20Stick/Dana20TwinStick009.jpg

All cleaned up and painted! Bling bling!:best:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Dana%2020%20Twin%20Stick/d20after002.jpg

EMTimZJ
09-12-2006, 10:00 PM
So how does one couple a 249 and EB D20?

Break out the calipers, tape measure, calculator, and brain power.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/249-DANA20PUBLIC.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Midshaftnonumbers.jpg

...and after just about 3 months later... the real product FINALLY showed up about 2 1/4 MONTHS after it was said to be finished:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/July52006017.jpg

Through hardened 4140, yes they are mill cut splines. 30 spline coarse for the inside of the 249, 28 spline fine for the D20 input shaft. Considering this is before the second reduction of the D20 and the diff gears, the Dturdy shafts, pinion (26 fine spline), heck even the Toy 8 pinion are only 27 fine spline and after more reduction. They will all probably go before this will. [EDIT: Factory Toy pinions are 29 fine spline, and the aftermarket pinions are 27 spline. Currently I have a factory 29 fine spline pinion]

Adapter plate made from 1/2 steel:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006007.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006008.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006009.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006010.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006011.jpg

Intermediate housing getting paint:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006006.jpg

dashnjgc
09-12-2006, 10:02 PM
what bellhousing did you use?

EMTimZJ
09-12-2006, 10:06 PM
Here is a shot side by side of the old 46RH + NP242 next to the whole NP435 + 249 + D20.

Rear DS is longer by 2" and the front by 1" using the new configuration:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/July52006009.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/July52006008.jpg

Pretty long, but shorter than stock. Also allows for plent of room for the D20 shift rails. I might not have enough clearance for the front output, worst case scenario is a flip the 249 and redrill my 1/2" adapter plate.

EMTimZJ
09-12-2006, 10:07 PM
what bellhousing did you use?

Bellhousing came from an 89 Ram with the 318/360 and NP435. I still need to cut a notch for the CPS. 88-91 Rams were available with the above configuration.

HTH

EMTimZJ
09-12-2006, 10:31 PM
I wanted to upgrade the stock brake system. I searched around and found a couple of suggestions such as XJ booter + '67 corvette master work, or XJ booster + E350 master work, or XJ + Chevy K20/K30 master work. All of these where supposed to "bolt-up" together. Well for some reason or another I could not get them to "bolt-up" with out spending more time that I wanted to. I read Kris's thread on the mid 90's F350 master and booster working very well.

I didn't mind making some modifacations to the firewall and surrounding area.

This is being performed on a full bodied ZJ so keep that in mind.

This mounting stud for the ditched ABS bracket had to go:
http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/Sept-42006012.jpg

You can see that I had to grind the backside of the shock-mount down so the booster could mount closer and flush to the firewall.

http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/July52006020.jpg

Another shot of the butcherd slots for the 4 mounting studs off the back of the booster to fit. Clutch master is also installed on the right. 93-95 ZJ's already had the knock out for this.

http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/Sept-42006013.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/Sept-42006014.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/Sept-42006015.jpg

The OD of the stud on the ZJ brake pedal is a little smaller than the ID of the hole in the booter rod. An extra steel shock bushing sleeve from my DT3000's was a good fit.

http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/July52006003.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/F350%20Brakes/July52006004.jpg

EMTimZJ
09-12-2006, 10:53 PM
I got the wrong flywheel at first... notice the notches for the CPS...

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/July52006.jpg

Here is the right one, 8 evenly spaced notches:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/August152006PoolPics002.jpg

Also, the section of the flywheel with the notches that the CPS reads off of is just slightly larger in diameter than the stock flex plate. I forget the exact amount (I have it written down SOMEWHERE) but I had to make a small spacer to go between the CPS mount on the block and the CPS bracket that mounts to it.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/August152006PoolPics006.jpg

Luk 23 spline 11" (measured 10.8") clutch disc...

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006001.jpg

Pressure plate installed and torqued to spec...

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-42006002.jpg

Nick
09-12-2006, 10:57 PM
How big of a difference did you notice with that brake upgrade.

EMTimZJ
09-12-2006, 11:03 PM
Well... it is not off the jack stands yet:D

ATL ZJ
09-12-2006, 11:03 PM
So did you swap in the DD Machine mainshaft? Doesn't look like the MadRooster kit. And isn't their a third manufacturer now specializing in converting the chain driven NP cases to crawlboxes now? And did you make the adapter plate yourself?

Everything looks great. Excellent tech here..

EMTimZJ
09-12-2006, 11:16 PM
So did you swap in the DD Machine mainshaft? Doesn't look like the MadRooster kit. And isn't their a third manufacturer now specializing in converting the chain driven NP cases to crawlboxes now? And did you make the adapter plate yourself?

Everything looks great. Excellent tech here..

Nope, that is a shaft I designed myself. I then sent my designs off to a guy to have it splined. No one makes a kit to join the 249 and D20, or even the 231 and D20. I traced out the shape of the 1/2" plate then had the machine shop cut it when they welded up the side of my 249. Unfortunetly I don't have the mad skillz (or TIG) to weld aluminum (yet!? :smt032). Then once home it was drilled and tapped to join the cases.

I wanted a doubler, and I wanted to see if I could do it cheaper than the kits out there. The 249 was free, the D20 was $75, modification for the 249 welding and cutting of the plate was $75, and the shaft was a little expensive at $450. Especially for a one-off production. Compare that to the d.d.machine product at $350 + the cost of a 231 I did not have + a flip kit ($$$) and it quickly exceeded the price I wanted to spend. Plus this was pretty fun!

6.68:1 x 2.72:1 x 2.46:1 x 3.54:1 = 158:1:supz:

Also, I'll be running around 2300 RPM's @ 70 mph on the highway in 4th.

-Tim

dashnjgc
09-13-2006, 01:00 AM
nice thanks what else do you need for the swap to a 435??? i want to do this to i have searched but came up with nuthin any help will be awsome

ATL ZJ
09-13-2006, 01:39 AM
So did you swap in the DD Machine mainshaft? Doesn't look like the MadRooster kit. And isn't their a third manufacturer now specializing in converting the chain driven NP cases to crawlboxes now? And did you make the adapter plate yourself?

Everything looks great. Excellent tech here..

ILikeMud
09-13-2006, 09:54 AM
Damn, quite the project.
I love the crawl box.

DJJordache
09-13-2006, 11:19 AM
6.68:1 x 2.72:1 x 2.46:1 x 3.54:1 = 158:1:supz:

maybe I missed it but are you gonna keep the 3.55 axle gears? if not then that crawl ratio could be CRAZY LOW on second thought standards usually have lower (numerically) gears... Anyways bad ass project! now I want a doubler too! I need to find a money tree:D

ogdak
09-13-2006, 12:21 PM
Very nice project

Skyline
09-13-2006, 04:05 PM
Awesome job. Can't wait to hear how it all works.

EMTimZJ
09-13-2006, 05:15 PM
Dash, I wouldn't say that is "all" you need, I still have to make a crossmember (or two) and a new skid, adjust the lengths of the DS's front and rear. Then there is the *issue of switching to a driver side starter, which is the only choice for this bellhousing. The rear DS is actually just going to be a whole new unit using a 1310 yoke at the D20 output and the toy-joint at the rear axle.

I wish I had the cash to upgrade the rear output to 32 spline and run a flange so I could run toy joints at both ends, they are very strong (right up there with 1410) and can go to 37*.

Jordan, yep I'm keeping the 3.54's (well 3.58 for the toy) in for now. I'm only going to be running 35's with that front D30. 3.54's and 35's may sound like a bad joke, but the NP435 has both a greater gearing span and lower gearing all around.

*issue being that I may have to rework the driver side downpipe.

-Tim

Kraqa
09-16-2006, 03:04 PM
that custome shaft looks awfly small for how long it is. i hope you dont' snap it. Great tech tho. looks liek it shoudl be awsome when done. i love the toy axles.

2jeepsforus
09-17-2006, 03:34 PM
Pretty Slick Tim..... I'm quite impressed! :smt023

Dave

EMTimZJ
09-19-2006, 12:03 PM
Kris, yeah it is longer than I wanted, but the way I used the stock intermediate housing from the EB drivetrain, it made for a REALLY simple adapter plate. Also, the minor diameter would still be the same even if it were shorter. The root of the smallest splined section should never enter the working diameter of the shaft. True this shaft will twist more (deg) since it is longer, but comparing this to axle shafts... some break more short shafts and some break more long shafts, it seems to be a toss up. The twisting can be helpful and detrimental.

-Tim

EMTimZJ
09-19-2006, 06:05 PM
I finished painting a few items this weekend:

Obnoxious green waggy steering box:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Waggy%20Box/Sept-182006003.jpg

Caliper brackets:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006004.jpg

I snagged a picture from somewhere else to show what the stock drain-plug and ring looked like:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/drain-plug.jpg

Just waiting to get caught on a rock or two!

Axle housing getting paint:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006001.jpg

Here is a pic of the welded and ground down drain plug along with the diff armor welded on:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006002.jpg

Caliper and bracket bolted on: (from www.sky-manufacturing.com (http://www.sky-manufacturing.com))

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006005.jpg

Use late 80's front chevy half-ton calipers with early 90's chevy truck rotors, standard cab.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006007.jpg

Yes, I'm using a wheel spacer / adapter to address the bolt pattern change (6x5.5 to 5x4.5) and width aspect... I was reluctant to do this, however after talking with the company on the phone and telling them exactly what I was using them for, they insisted that if they were properly torqued, there would be no issues. We'll see how it works!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006008.jpg

Wrenching out the bottom studs to be replaced with regular 8mm x 1.25 bolts that will serve as the new "drain plugs" as the OEM was welded and ground:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006009.jpg



-Tim

BlaineWasHere
09-21-2006, 11:54 AM
I need to find a money tree:D

Tim needs to find a money tree too... If only has 46RH had not crapped out on him he would still have deep(er) pockets. This Jeep is making him BROKE! But he loves it!:goodman:


AWESOME write up you are doing Tim!

BlaineWasHere
09-21-2006, 11:57 AM
I finished painting a few items this weekend:

Obnoxious green waggy steering box:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Waggy%20Box/Sept-182006003.jpg




I can think of one other ting you have obnoxiously painted!:flipoff2:

spykosshow
09-21-2006, 12:20 PM
:smt003


http://i16.photobucket.com/albums/b11/EMTimZJ1/Random%20Shot/Sept-182006016.jpg

EMTimZJ
09-21-2006, 12:31 PM
Yep, that is Blaine with my old 249 front output yoke that he is using for his 247!:rofl:

ELLLLLIOTTTTT
09-21-2006, 12:42 PM
Tim,

we just put that same diff cover on the pathy, it is super stout, and only $25. The progress is looking good. (minus Blaine's gayness :D .)

BlaineWasHere
09-21-2006, 11:43 PM
(minus Blaine's gayness :D .)

I'm not even going to try and deny it... I look like a duche bag in that pic.

thanks for the yokes Tim!

EMTimZJ
09-22-2006, 11:39 AM
Tim,

we just put that same diff cover on the pathy, it is super stout, and only $25. The progress is looking good. (minus Blaine's gayness :D .)

Thanks Elliot! Yeah, that diff cover is great, it was hard to pass up for the price! (I think mine was $30-$35 though? Oh well! Still a good price:cool:)

This weekend I should be finished with the e-locker wiring and be able to complete the axle assembly and have it ready to put in.

-Tim

Airmanwoody
09-22-2006, 03:44 PM
You need to get this thing rolling under it's own power. It's sad to see it sitting like it is.

Like the buildup though.

My ZJ goes under the knife around January for the newer lift components, and possibly a STROKER!

ELLLLLIOTTTTT
09-28-2006, 02:48 AM
http://img131.imageshack.us/img131/5796/dscf0536vi6.jpg

these are good ass diff covers. And I'm a good looking background filler. :smt110

spykosshow
09-28-2006, 10:11 AM
these are good ass diff covers. And I'm a good looking background filler. :smt110


You look like you're struttin your stuff back there! :flipoff2:

EMTimZJ
10-01-2006, 03:00 PM
http://img131.imageshack.us/img131/5796/dscf0536vi6.jpg

these are good ass diff covers. And I'm a good looking background filler. :smt110

Are you (or the pathy owner) leaving the bottom drain plug in place?

EMTimZJ
10-01-2006, 03:14 PM
DIY coil hose for the diff vent. 1/4" vinyl hose wrapped around a vacuum cleaner extension:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006020.jpg

Hot water bath:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006021.jpg

Done:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006022.jpg

Wired up the locker switch and LED during the UMichigan v. Minn game. Locked Position:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006023.jpg

Unlocked Position:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006025.jpg

Cue-Ball
10-01-2006, 03:40 PM
Looking great so far Tim.

OverkillZJ
10-01-2006, 05:18 PM
The colored parts are just great... gave me a good laugh...

ILikeMud
10-01-2006, 05:33 PM
Looking good man.

spykosshow
10-09-2006, 04:32 PM
Any updates?

Kraqa
10-09-2006, 06:18 PM
so much effort into the diff breather when you can get a coilled air lien for $3.00

EMTimZJ
10-11-2006, 06:25 PM
so much effort into the diff breather when you can get a coilled air lien for $3.00

Yes you are right. I was going to go the route you did with the D70, with the quick disco coiled air line, however I noticed the housing was already tapped 1/8" NPT so that made it pretty easy with this fitting + the 1/4" hose.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006045.jpg

Toy 8 fully dressed waiting to get put in:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Toyota%208%20Inch/Sept-182006044.jpg

EMTimZJ
10-11-2006, 07:13 PM
So as I reluctantly expected, there was not enough room for my front driveshaft. 249 reduction box needs to get flipped.

Lined everything up, mid-shaft is centered in the 249 and in the D20 input. marked out where the new holes need to go:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006021.jpg

With the proper holes marked, the drilling fun begins:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006022.jpg

Drilled and tapped 1/4" NPT for the sight tube:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006025.jpg

Somewhere in the middle of tapping my cheap tap handle broke, piece of junk:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006035.jpg

Big thanks to Jordan (DJJordache here on MC) for mailing me his old 249 shift fork assembly. Some time during my 249 tear down I lost the sector switch roll pin. Jordan was going to just send me that and then he found that his was welded in! Mine looked to be welded in at some point, so I have no clue how I lost it or where it went. The fork removes from the rod by pulling the small retaining cross pin. My original rod was already cut to proper length so I just swapped them over. Thanks Jordan:smt039

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006040.jpg

Instead of welding up the old holes, grinding them flat, repainting, I just plugged them with 3/8" long set screws. Also a look at the sight tube for an easy check on fluid level.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006047.jpg

AgitatedPancake
10-11-2006, 07:48 PM
damn...lookin awesome man!

ZachJ
10-11-2006, 07:55 PM
damn...lookin awesome man!

What he said.

DJJordache
10-12-2006, 10:12 AM
Thanks for the thanks! just helping out a fellow Jeeper:smt038 Keep up the good work!

EMTimZJ
10-24-2006, 06:12 PM
I did not have much time to work on the rig the past weekend. Since I had to flip my 249 reduction box, I had to re-drill my transmission adapter. (or get a clocking ring and mess around with seal engagement) This method was faster and easier to do.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006048.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/Sept-182006049.jpg

I cleaned off the previously messy basement work bench and went to work. It turned out fine and was not nearly as painful as I originally thought.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/OCT-22003.jpg

I kinda had to mentally prepare before I took a blade and grinder to such a pretty adapter:eek: ... but it just had to be done, I'm sure you understand!:D

-Tim

ILikeMud
10-30-2006, 04:36 PM
Nothing like chopping up something purdy :D

So I must ask Tim, aren't Toyota axles 6 lug? Are you still using a d30 front? How are you getting around the different bolt patterns.

EMTimZJ
11-02-2006, 12:29 PM
Nothing like chopping up something purdy :D

So I must ask Tim, aren't Toyota axles 6 lug? Are you still using a d30 front? How are you getting around the different bolt patterns.

Yeah, I think I measured about 15 times before I marked it, then about 15 times after I marked it:D

See post #31, second picture from the bottom. My toy-8 came from a 4wd version, which means 6x5.5 lug pattern. The V6/turbo 2wd versions have a 5x4.5 lug pattern, however they are a harder to find. The non V6/turbo 2wd axles are the Toy 7.5" diff with 27 spline axles and weaker housing.

-Tim

monkeyevil
11-05-2006, 02:20 AM
Love the pretty steering box :D

EMTimZJ
11-05-2006, 04:08 PM
Love the pretty steering box :D

Hey Daryl, nice to see you made it over here!

EMTimZJ
12-19-2006, 03:20 PM
NP435 internals:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild003.jpg

Shift assembly:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild004.jpg

Installed the correct bearing retainer, Dodge style on the left, Ford style on the right.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild011.jpg

OD of the Dodge = 1.236"
OD of the Ford = 1.430"

The two throwout bearings have different ID's and there attaching methods to the clutch release arm are different, just get your hands on the right retainer and life is good!

Also, there are two different finger lengths for the NP435 shifters; the one I am using is on top:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild006.jpg

Big thanks to my buddy Aron for loaning me the kerosene heater!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild033.jpg

Notice the notch for the CPS (crankshaft position sensor) on the stock 46RH bellhousing, there is no notch on the 435 bellhousing...yet...

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild015.jpg

marked:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild017.jpg

1/4 way through...

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild018.jpg

CPS notch cut, bearing retainer on, throwout bearing, release arm, and slave cylinder installed:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild021.jpg

Cue-Ball
12-19-2006, 03:22 PM
Looking good man.

Keep up the good work.

Dirk

ILikeMud
12-19-2006, 03:25 PM
Looks good Tim.

EMTimZJ
12-19-2006, 03:31 PM
The trans was too tall to set on the ATV jack and then be slid under the ZJ, so I put it on the creeper to get it under the ZJ and then hoisted it onto the ATV jack.

Keep in mind I am trying to do this by myself, lifting that 435 around under the vehicle is a pain!

I rigged some rope to the trans from inside the ZJ down through the hole:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild027.jpg

On the inside were two jack stands with a piece of DOM running between:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild028.jpg

This way I was able to go back and forth raising it one notch at a time until I could slide the ATV jack underneath:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild029.jpg

Much easier to manuver this thing now!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild031.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild030.jpg

Had to cut a bit to get enough room for the top cover to clear:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild034.jpg

Popsicle
12-20-2006, 12:41 AM
absolutely amazing..

PhilZJ
12-20-2006, 03:01 PM
Tim,
This is a project and a half!!! Can't wait to hear it's up and running!
Hope to see ya soon!
If I lived about 500 miles closer, I'd be your gofer.

Phil

EMTimZJ
12-21-2006, 11:52 PM
Thanks for the encouragement! Phil, we’ll get out on the trail soon! :smt039

Tunnel cut shot from the top:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild035.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild036.jpg

So this was a little red-neck, but I could not find the reciprocating saw (sawzall) ANYWHERE. I have not seen it around in years, but I had a brand new package of blades from who knows where so go figure. I rigged a recip blade to fit the jig saw and it actually worked great. The “proper” jig saw blades were too short for these cuts:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild037.jpg

The result:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild038.jpg

Getting the trans to mate to the engine was pretty tough. I’m by no means master mechanic so for some I am sure this is a breeze. Anyway, laugh at me if you must, but they are now mounted together! I got an engine hoist (Aron, thanks again!) and pulled the engine forward and dropped it down a little. This allowed more room to get at the bellhousing bolts (five of them) across the top, and actually get the angles right for the input shaft to slide in. Huge thanks to my buddy John for helping me get this accomplished, what a night and day difference it makes with two people! Oh yeah, and John’s wrenching skills >>> my wrenching skills :doh:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild040.jpg

With the engine mounted back in place, this is where the shifter column comes up through the floor.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild042.jpg

Center console pieces back in place… just like stock right?:cheer2:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild043.jpg

I’m pretty sure I will lose the VIC, but I’m not too concerned.

Shot from underneath:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild044.jpg

Here are some good pictures showing where the starter will end up, the drivers side down pipe will have to get modified. It is after the flange for the manifold and I should have enough room for re-routing.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild045.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild046.jpg


http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild047.jpg

-Tim

Airmanwoody
12-22-2006, 02:29 AM
Wow Tim.

You sure the shifter will work in that location? I think you have an issue there. Even with a severe bend, I think it will be a challenge.

I'm starting to think a NV3500, 3550, or 4500 would've been easier.

I don't know how much you've got into this install, but a local guy up here got a brand new NV4500 with all required components to install in his YJ for around $1750, shipping was a bear up here, but it was only a few bucks more than getting the necessary adapters, bellhousing and stuff and buying a used 4500 from a junkyard.

Glad to see parts going in the Jeep. I'm sure she's complaining about how long it's been since it's been rolling on it's own wheels.

Keep up the good work.

MaineZJ
12-24-2006, 04:24 PM
sweet build.
great to see someone finally swap in a Toy rear.

Skyline
12-24-2006, 05:08 PM
Definately an "outside the box" type build.

BlaineWasHere
12-24-2006, 09:29 PM
Tim I am glad you FINALY got the tranny bolted up. Good thing we have ONE friend (john) who knows what he is doing... becuase aron and I were not much help the night before.

Give me a call on tuesday and let me know how things are going!

DJJordache
12-24-2006, 09:58 PM
NICE WORK! reminds me of some of the work I did on my 4wd swap, I think I really enjoy the build/fabrication the most on our Jeep addiction projects:rolleyes:

Airmanwoody
12-24-2006, 10:25 PM
Anything since getting it bolted?

AprilzWarrior
12-24-2006, 11:23 PM
I like the old school way of installing the tranny, I have the same device for model T


AW

EMTimZJ
12-31-2006, 02:33 AM
Thanks for the comments guys, she should be rolling soon!

Woody, yeah the shifter is pretty far forward, but I’ll make it work somehow.

So the mid-shaft joining the D20 and 249 was 3/8” of an inch too long. Yes, I need a real lathe, but this worked just fine! Powered by the drill, I was able to get a square cut while it was spinning.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild051.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild052.jpg

All finished!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild053.jpg

Yes, I went pretty slow and I’m sure it did not get above 900 degF to alter the heat treatment.

Before, the D20 input bottomed out on the mid shaft and could not seat fully in the intermediate housing.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild054.jpg

After the cut, it seats perfectly!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild055.jpg

Spline engagement just perfect after the cut:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild056.jpg

EMTimZJ
12-31-2006, 02:41 AM
I started on the new cross member and transmission support. At first I tried to use the old ZJ rubber mount and bracket just because it was sitting there, but it ended up being too tall.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild063.jpg

It would just hang down too low:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild064.jpg

I ran to Napa and purchased a different mount (PN 620-1091) and this will work much better:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild065.jpg

This will make more sense when I have the finished support and cross member, but basically it is hard mounting to the rear of the transmission (on the Novak adapter) and the intermediate housing of the D20. This way that long combo will be supported nicely instead of just at one end.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild069.jpg

ogdak
12-31-2006, 05:30 AM
Very nice progress

minydigger
12-31-2006, 12:00 PM
The new mount (PN 620-1091) was it for a dodge dokota if so I used the same one when I switched out to a XJ high clerance crossmember.

EMTimZJ
12-31-2006, 10:46 PM
Not sure what the stock application is on the mount, I just went to Napa and looked in the book until I found one I liked.

Cross member is 90% finished, just need to drill some holes and make the support for the intermediate housing:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild072.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild073.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild074.jpg

Half way through my $9.00 Harbor Freight wheelie chair started to break!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild075.jpg

Welded, and just because I had it, a shot of obnoxious green paint!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild.jpg

Capped and sanded the holes:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild076.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild077.jpg

H3RESQ
01-01-2007, 09:39 PM
WOW! Cool stuff. I like your unique choices. Might be the only grand to ever have a toy rear.(first i've seen anyway)
Great read. Can't wait to see it finished.

spykosshow
01-01-2007, 10:14 PM
How come the piece you welded on to the crossmember isn't perpendicular to the crossmember?

ELLLLLIOTTTTT
01-02-2007, 02:10 AM
maybe because the mount on the NP435 isn't perpendicular to ZJ frame rails... wow, who'da thunk it. :flipoff2:

spykosshow
01-02-2007, 10:29 AM
maybe because the mount on the NP435 isn't perpendicular to ZJ frame rails... wow, who'da thunk it. :flipoff2:

So why not offset it and make it perpendicular? :flipoff2:

EMTimZJ
01-03-2007, 01:44 AM
Well you both are sort of half right. :D

The 435 mount is centered, but the other end where it mounts to the D20 intermediate housing is not centered, so that is why it is angled the way it is.

spykosshow
01-03-2007, 11:23 AM
You're not done yet????

EMTimZJ
01-03-2007, 03:38 PM
No, are you? Get back to work, I bet mine rolls before yours does:flipoff2:

BlaineWasHere
01-03-2007, 08:13 PM
Tim you said it would be rolling tonight!!! is it?

EMTimZJ
01-04-2007, 02:29 AM
No, I couldn't find the bolts for the int. housing to the D20, I'll pick them up in the morning. I took that thing apart about 7 months ago, I guess it was a good thing those are the only parts missing!

Anyway, I did get some work finished. Waggy box is in, just need some longer bolts for the steering brace I made before I can bolt that in and put the front sway bar back in.

Cut some more floor to make room for the 249 box:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild083.jpg

Pulled just about the entire exhaust (minus the manifolds)

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild080.jpg

Put the 13 needle bearings back in for the D20 input shaft:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild084.jpg

They ride on the end of this:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild085.jpg

Hopefully it will be rolling on these tomorrow!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild087.jpg

spykosshow
01-04-2007, 09:33 AM
No, are you? Get back to work, I bet mine rolls before yours does:flipoff2:


But will it run under it's own power? :flipoff2:

8WR_ZJ
01-04-2007, 10:40 AM
nice work on the rig. we talked earlier about the doubler set up. we are doing the same thing except i am doing away with the intermediate housing of the dana 20. keep it up its looking great!

spykosshow
01-04-2007, 08:19 PM
You are going to beat me. :( I have to go find an AW4 dust shield cause I'm stupid and didn't realize the 42re dustshield and the aw4 dustshield are different. DOH!

EMTimZJ
01-06-2007, 02:09 AM
Charlie, you will probably beat me in getting it running, but I got ya in the rolling race! :smt044

8WR, if you can get rid of the intermediate housing then that will be great, especially if you are NOT running a short transmission. There were two reasons I used it, #1 it made for a really easy way to adapt/mate the two, #2 I could get away with the length since the 435 is so short.

More progress:


I had to make a little room for the D20, BFH fit the bill:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild088.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild089.jpg

Plenty of room now:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild090.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild091.jpg

Not truly “flat” but it is tucked up there enough, at least more than the old transfer case was:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild092.jpg

Note that the whole drive train will be lifted about 1” higher than what is pictured above.

Good news is that the cross member is in and fits…

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild094.jpg

Bad news is that the mount I had running lengthwise between the 435 bracket and the D20 intermediate housing was too tall, back to the drawing board to make a shorter trans mount.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild093.jpg

EMTimZJ
01-06-2007, 02:19 AM
Another small hurdle; I realized that the lower link tabs on the toy 8” were only ½” and the control arm bolts were 9/16” ( well technically 15mm ) . Well easy fix, just drill them out real quick, right? Theoretically yes if I had a right angle drill, maybe someday I’ll add that to the arsenal. There was not enough room to get the drill in because of the third member, and the sway bar tabs were blocking the way from the other side. I had to strip the whole axle down to drill out the dumb tabs. Looking on the bright side, I am really good at this now and it only takes 10 minutes down and 10 minutes up for the toy 8”.

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild095.jpg
With that finished, the axles went in, the tires on, and she actually moved!!!

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild097.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild098.jpg

BAM! 32” divided by 8 months gives about 4 inches a month, or about an inch a week!

How she sits now:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/ZJBuild099.jpg

SuicideTireZJ
01-06-2007, 07:41 AM
How do you figure? 4"/ month is barely more than 1/2" a week by my calculations, or roughly 1/14" a day....

Just givinv you shit cause I'm drunk. Yoiur jeep is neat.

BlaineWasHere
01-06-2007, 11:16 AM
FUCK YES! Happy to see her supporting her own weight... You have to retire those jack stands now... they are too tired from holding your Jeep up for soooo Long...

spykosshow
01-06-2007, 11:50 AM
Looking really good!! Glad to see she's rolling under her own weight. I'm getting close. I have just a few bolts I need to pick up and then mine is up and running again. Mine never stopped rolling though... :smt066

EMTimZJ
01-06-2007, 03:26 PM
Suicide, I was just using the approx 4 weeks per month when I did that :D

Blaine, it was a little weird pulling the jackstands out, I kept double checking that the axles were really there, attached ok, and the springs were supporting the weight LOL

Charlie, you will certainly get me on the running race, many more things still have to be finished. Brake lines/cutting brake wiring, clutch line, D20 shifter linkage, exhaust, and driveshafts just to get it running. I can't forget steering links either. Then tweaking the bends in the 4 shifters that will be there and making a center console to hide that hole.

AgitatedPancake
01-06-2007, 03:26 PM
How do you figure? 4"/ month is barely more than 1/2" a week by my calculations, or roughly 1/14" a day....

Just givinv you shit cause I'm drunk. Yoiur jeep is neat.

Lol...since when are there 8 weeks in a month?

BlaineWasHere
01-07-2007, 10:54 PM
Lol...since when are there 8 weeks in a month?

If there was 8 weeks in a month Tim might actaully have the Jeep running!!!

ArloGuthroJeep
01-31-2007, 01:15 PM
Looks great Tim, you actually may make it to GSW this year:-O

spykosshow
01-31-2007, 01:37 PM
Yea, whats the progress on this bad boy?

Airmanwoody
02-02-2007, 07:16 PM
Get it to roll under it's own power yet?

ILikeMud
02-06-2007, 09:20 PM
Hey Tim,
Tried to PM you but your box is full.

Where did you buy your Toy E-Locker from?

EMTimZJ
02-14-2007, 02:28 PM
Not too much progress lately. I had to return the reddy heater, and it was 20degF in the garage this weekend. A tad bit cold:coffee:

Primed the steering box brace in the basement and ran some brake lines for the line locks that will be used for cutting brakes.

-Tim

ras2001wj
02-15-2007, 10:56 AM
Not too much progress lately. I had to return the reddy heater, and it was 20degF in the garage this weekend. A tad bit cold:coffee:

Primed the steering box brace in the basement and ran some brake lines for the line locks that will be used for cutting brakes.

-Tim
gunna be ready for GSMW there? jk seems like your doing most if not all of the planning so far...... love the buildup though:partyman:

Airmanwoody
02-16-2007, 05:56 PM
Not too much progress lately. I had to return the reddy heater, and it was 20degF in the garage this weekend. A tad bit cold:coffee:

Primed the steering box brace in the basement and ran some brake lines for the line locks that will be used for cutting brakes.

-Tim


Wuss,

20 degrees isn't cold. It was that outside yesterday and I took my jacket off for awhile because I was sweating.


Hurry up and finish your build. My K10 Burb is about to undergo a swampy style roof chop and become the next rig.

ArloGuthroJeep
05-24-2007, 11:12 PM
Ok Tim, it has been 3 months...your junk running yet?:flipoff2:

spykosshow
05-25-2007, 06:25 PM
Yeah what the hell is going on....don't make me call you again.

spykosshow
05-30-2007, 11:58 PM
so so so, you done yet?

ArloGuthroJeep
05-31-2007, 12:18 AM
Maybe if I ban you from JF Tim, you'll actually work on your Jeep:flipoff2:

spykosshow
06-03-2007, 02:10 PM
Ok, he's posted on this forum, but he hasn't posted in here....TIM?!

Katesdad
06-03-2007, 06:57 PM
Get to work.... I need to know how to make the 35s jive with the 3.5!

ajmorell
07-02-2007, 04:14 PM
Tim, I wanna see this thing!

BlaineWasHere
07-03-2007, 10:16 AM
Tim, I wanna see this thing!

I Have seen it (like every day)... its not done yet.

ajmorell
07-03-2007, 10:27 AM
I Have seen it (like every day)... its not done yet.


I figured it wasn't done yet, but I still want to see it.


Come to think of it, is anyone's rig ever "done"?

DJJordache
07-03-2007, 10:31 AM
Come to think of it, is anyone's rig ever "done"?NEVER! I just finished my longarms and now I'm planning the next mods to be done, haha I'm screwed:D

ArloGuthroJeep
07-03-2007, 10:56 AM
I am starting to wonder if Tim isn't actually taking pictures of his neighbors rig and posting them up as his own...and lately his neighbor hasn't been working on it so Tim can't post up any new pics of "his" rig...

BlaineWasHere
07-03-2007, 12:26 PM
I am starting to wonder if Tim isn't actually taking pictures of his neighbors rig and posting them up as his own...and lately his neighbor hasn't been working on it so Tim can't post up any new pics of "his" rig...

No it really is Tim's... he is just not working on it.

ArloGuthroJeep
07-03-2007, 12:49 PM
How cute, you're defending him:smt055





:D

EMTimZJ
07-03-2007, 12:53 PM
Yeah yeah, I have not had very much time lately. I'll post up some progress soon.

Andy, you can stop by anytime you want.

-Tim

BlaineWasHere
07-03-2007, 01:06 PM
How cute, you're defending him:smt055





:D

I have to or he won't build my Jeep to when he is done...:flipoff2:

ajmorell
07-03-2007, 01:21 PM
Yeah yeah, I have not had very much time lately. I'll post up some progress soon.

Andy, you can stop by anytime you want.

-Tim


Maybe I'll just swing out there and check it out when I get those gears from you. Call me or PM me when works good for you.

EMTimZJ
07-21-2007, 12:03 AM
Finally some progress pictures.

Rear fenders trimmed:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007001.jpg

Line Locks mounted:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007002.jpg

You can also see the rear e-locker switch + wiring in the above photo.

Swagelok valve for e-brake and proportioning valve in: (not in final locations:smt069)

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007003.jpg



Shifter bent: (it is in 1st gear right now)

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007004.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007005.jpg

Front and rear brakes all plumbed:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007006.jpg

I used my left over RE rear SS line for the T in the front brakes:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007008.jpg

Clutch is bled, still need to do the brakes though. I need to hook up the steering box lines too. Many little things left!

-Tim

ATL ZJ
07-21-2007, 11:58 AM
That is really good for first gear. My hand is about inside the radio on mine using a mangled and twisted stock np435 shifter..

nierace
07-23-2007, 09:35 AM
Looking good Tim

ajmorell
07-23-2007, 10:06 AM
Looks good Tim. I plan on heading out there this week to grab those gears, I'll check out the progress in person.

EMTimZJ
07-31-2007, 11:48 PM
My angle grinder started to spark and almost catch fire in my hand, so I had to fix that. Not the best start to a day of cutting.

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007009.jpg

Offending bare wires removed and new section wired in:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007011.jpg

Rolled the ZJ out of the garage and did some garage cleaning. Clean garage floors are nice:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007012.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007013.jpg

Finished up drivetrain mount 3.0:

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007015.jpg

The long piece mounts to the NP435 transfercase adapter and the D20 intermediate housing. I used a leaf spring bushing pressed into a piece of tube for the rubber mount. 9/16" for the through bolt, 1/2: bolts for mounting to the cross member and D20 int. housing, and 3/8" bolts for the 435 mount. (Yep I am getting a longer through bolt!)

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007019.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007020.jpg

Napa PN for the mid 90’s S-10 leaf spring bushing is 274-6591. For $7 it will work just fine. Readily available if it ever needs replacing as well.

I wired in some terminal strips for power and ground so I don’t have to run wires to the battery anymore.

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007016.jpg

Drilled a hole here, in the passenger foot well, and ran a wire into the ‘frame’ rail.

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007018.jpg

Wire comes out just under the battery tray.

http://i79.photobucket.com/albums/j128/EMTimZJ11/July172007017.jpg

DerekL
08-01-2007, 12:02 AM
I love this project.

ArloGuthroJeep
08-01-2007, 12:35 AM
Get cracking Tim, summer is almost over!

Looking good though!:)

BlaineWasHere
08-01-2007, 08:42 PM
Trans mount is straight baller! I saw it in person and it looks factory!

ArloGuthroJeep
08-01-2007, 08:46 PM
Factory = weak:flipoff2:

ILikeMud
08-02-2007, 06:49 PM
Can't wait to see it finished Tim.

ajmorell
08-03-2007, 11:17 AM
Tim you need to get this damn thing done so that you can make a trip to westbranch before the end of the summer

BlaineWasHere
08-03-2007, 08:46 PM
Tim you need to get this damn thing done so that you can make a trip to westbranch before the end of the summer

I would love to go back to the badlands in early october if you ever get back to GR area after school starts. Is drummond open all year?

ELLLLLIOTTTTT
08-04-2007, 01:31 AM
dont let Blaine anywhere NEAR your rig. NP435's were just not meant to have pink yokes.

BlaineWasHere
08-05-2007, 12:30 AM
dont let Blaine anywhere NEAR your rig. NP435's were just not meant to have pink yokes.

247's were... Tim painted the damn yoke pink... which is still pink BTW...

ajmorell
08-05-2007, 10:18 PM
I would love to go back to the badlands in early october if you ever get back to GR area after school starts. Is drummond open all year?

Yeah I think October would be ideal for the badlands, but i got some work to do before i go anywhere. Do you have any interest in going to westbranch or even silver lake or something?

BlaineWasHere
08-05-2007, 11:14 PM
Yeah I think October would be ideal for the badlands, but i got some work to do before i go anywhere. Do you have any interest in going to westbranch or even silver lake or something?

How was this past weekend at the badlands???

I do have interest in those places if it is going to be worth it. I don't want to spend the gas money if it is not really worth it these days.

EMTimZJ
09-02-2007, 01:01 AM
Not much has been finished on the ZJ in a while; I have been busier than normal. I did get my shifters and shifter knobs finished though.

I drilled and tapped a 34mm impact socket to use as my NP435 shifter.

http://i79.photobucket.com/albums/j128/EMTimZJ11/P8060590.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/P8060589.jpg
Drilling and tapping the hardened steel was ridiculous (it took forever!) but I am happy with the way it turned out.

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020601.jpg

I also drilled and tapped the solid rod I used for the D20 shifters and 249 reduction box to use deep well sockets as the shift knobs.

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020605.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020600.jpg

Dana 20 twin sticks:

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020603.jpg

249 reduction box shifter (right now it is 1:1)

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020604.jpg

I drilled and tapped ¼” NC then ran a hex bolt + washer from the top. I did a taper in a square shape on the bench grinder so the 3/8” drive sockets do not wobble at all.

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020606.jpg

Longer through bolt on the drive train rear mount:

http://i79.photobucket.com/albums/j128/EMTimZJ11/P9020599.jpg



-Tim

corrupt143
09-02-2007, 03:11 AM
Your shifters have a lifetime warranty! Nice.



Plus, if you carry the allen wrench with you, you'll have the sockets handy if you ever need them. Nice way to conserve space in the tool box. ;)

ogdak
09-02-2007, 07:34 AM
Nice place to put spare sockets.

adam99wj
10-04-2007, 06:07 PM
nice build, im planning a 231 to d300 doubler now for the wj , i cant believe i never read up on this build till now hahah , nice shifter knobs

ELLLLLIOTTTTT
01-03-2009, 09:13 PM
This needs to be updated in the worst kind of way!

ZJcrawler45
04-14-2009, 04:23 PM
Awesome build ! I can't wait til i have my own garage.

ajmorell
04-22-2009, 03:33 PM
According to Tim this thing runs & drives now.....but I'll believe it when I see it.

ArloGuthroJeep
04-22-2009, 06:02 PM
He lies!

Kraqa
04-22-2009, 11:35 PM
ya WTF?

is this thing done?

spykosshow
06-10-2009, 09:37 PM
ya WTF?

is this thing done?


Soo. There's no way this thing ISN'T done yet.

DJJordache
06-10-2009, 10:50 PM
yeah this needs updates bad!

ajmorell
06-11-2009, 03:39 PM
Last I heard it runs and drives but apparently it overheated on the way down to the Badlands for GSMW. Tim will have to confirm that though.

Fish1200
07-11-2009, 10:30 AM
wow. great drivetrain. jelous of the manny swap on V8

Fish1200
07-11-2009, 09:26 PM
Here is a shot side by side of the old 46RH + NP242 next to the whole NP435 + 249 + D20.

Rear DS is longer by 2" and the front by 1" using the new configuration:

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/July52006009.jpg

http://i79.photobucket.com/albums/j128/EMTimZJ11/Drivetrain/July52006008.jpg

Pretty long, but shorter than stock. Also allows for plent of room for the D20 shift rails. I might not have enough clearance for the front output, worst case scenario is a flip the 249 and redrill my 1/2" adapter plate.
so did u switch to driver side starter?

it usually runs fine
08-13-2010, 04:57 PM
Whats the deal with this shit....? Update mandatory!

BigClay
08-13-2010, 09:46 PM
Looks like he hasn't been on the site since February, so probably not going to get an update any time soon.

cowboy63b
08-14-2010, 02:59 PM
what the fuck man!?!? i wanna know if shes a go!

ArloGuthroJeep
08-14-2010, 03:33 PM
Tim is what we call a web wheeler:flipoff2:

cowboy63b
08-15-2010, 02:25 PM
:gayflag::booya:

hansshanks
02-23-2016, 09:12 PM
Reviving a old thread. Did this ever get completed and on the road. I am currently considering using a np435 myself in my zj.