Diesel ZJ

[ATL ZJ]

Very cool rig. How much weight did you gain over the 318?

Emissions-wise, here in Atlanta diesels are exempt. But for gassers there are a few ways to get waivers, including repairs in excess of certain dollar amount and proof that the vehicle is being stored/used out of state.

[CurtP]

[ILikeMud]

Fucking sweet!

[Matt]

Nicely Done!

[DieselZJ]

The motor mounts are completely different from those pictures...those were my first attempt, and there was too much vibration.

As for emissions in NY, I raised the GVW up to 8600lbs, making it emissions exempt. I think they still require a visual inspection of emissions equipment for gassers, but they don't need to be plugged in to the scanner. The only thing involved was registering the jeep for more weight, which cost an extra $30 or so for the 2 year registration.

[DieselZJ]

Very cool rig. How much weight did you gain over the 318?

about 150~200lbs

[DieselZJ]

I got started on the NV4500 swap yesterday. I had a pedal assembly out of an xj that I hacked up and added the clutch pedal to the zj assembly. It worked out ok and didn't take very long. I also drilled out for the master cyl, it was already marked. I'm waiting on a new input shaft, and a clutch/flywheel set before I pull the automatic out.

[nate]

Where is that :fwap fwap fwap: smiley when you need it? That is kick ass!

[ATL ZJ]

These pics are killing me. You did the pedals the smart way-out of the Jeep. Doing them upside down on your back in the dark is NOT the most intelligent way.


Anyways, the glued-in blockoff plate for the clutch master is great isn't it?

[OverkillZJ]

Freakin' rock!

[mudforblood]

I did the same thing when I did my ax-15 swap. The XJ pedal ass. is not the same as the ZJ. The pin/pivot point will need extended to the drivers side farther to line up with the stock ZJ clutch MC mounting location. I cut my XJ pedal at the red line and extended it and reinforced some. Also the stock XJ pedal doesnt seem to have enough travel to fully disengage the clutch. I had to redo mine a few times to make it work.

[Skyline]

I've never actually seen a ZJ with a manual, I assume they are rare, but don't they exist? Or are they just for non-US ZJs or something? Can't you get a ZJ manual pedal assy right from the dealer or a junk yard? Or were you just trying to save a bunch of money and using what was on hand?

[SOLITUDE]

93-94 were the years of the Manual ZJ. But only behind the 4.0. I'm not sure if you can still order the assembly from the dealer.

[RebelGT]

you can order the Clutch Pedal Bracket, and the Master/Slave Cylinder Assembly, I picked up both, but only ended up using the Cylinders for my swap, and the XJ pedal assembly was modified to fit.

[DieselZJ]

I did the same thing when I did my ax-15 swap. The XJ pedal ass. is not the same as the ZJ. The pin/pivot point will need extended to the drivers side farther to line up with the stock ZJ clutch MC mounting location. I cut my XJ pedal at the red line and extended it and reinforced some. Also the stock XJ pedal doesnt seem to have enough travel to fully disengage the clutch. I had to redo mine a few times to make it work.

Thanks for the info. It looked like the master cyl hole was too far to the left, but I don't have the master in there yet, so I couldn't tell if it just looked wrong, so I held off on cutting it up.

[DieselZJ]

I've never actually seen a ZJ with a manual, I assume they are rare, but don't they exist? Or are they just for non-US ZJs or something? Can't you get a ZJ manual pedal assy right from the dealer or a junk yard? Or were you just trying to save a bunch of money and using what was on hand?

I'm sure I could have sourced pedals out of a zj, but it was just easier to modify what I had. I probably spent less time making what I had work than I would have spent on the phone searching for the pedal assembly and explaining to some junk yard goon what I wanted.

[ILikeMud]

I've never actually seen a ZJ with a manual, I assume they are rare, but don't they exist? Or are they just for non-US ZJs or something? Can't you get a ZJ manual pedal assy right from the dealer or a junk yard? Or were you just trying to save a bunch of money and using what was on hand?

Friend of mine had a 94 Grand Cherokee with the factory 5spd.
Very very very rare!

[fsjtrash]

HOLY crap i LOVE THAT FREAKIN THING! what did it cost ya?

[DerekL]

You can't just buy one of these.

[Kraqa]

thats cool to say the least

[DieselZJ]

I got the NV4500 in and drove it down the road today, it's awesome. I don't have any pics cause someone borrowed my camera. It was a large pain in the ass to get everything to fit and work, it took 4 days of work to complete.

I have a crawl ratio of 56.92:1, so I top out at 4.5mph and I can let the clutch out with my foot on the brakes pretty good, and it doesn't stall. It also puffs more black smoke now. I'll post some pics when I get a chance

[nateman54]

Any other oil burners that you think will fit?

[DieselZJ]

the 4 cyl engines out of isuzu box trucks would fit better, along with the little mitsubishi fuso engines. I haven't done any research on them though. There is a section for those engine swaps on 4btswaps.com

[nateman54]

Thanks.

[SOLITUDE]

You know.... I thought the 4bt would hang down a lot further than it actually does. Nice Job.