Thread: Project Hugs Version 4.0

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  1. #76 Re: Project Hugs Version 4.0 
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    Well, it's mobile and complete. Buttoned up all the welding and such in my buddy's shop today. Seam sealed the crap out of all the joints, and threw some paint on things to seal it up. Rear bumper is back on and trimmed up on the right side. The bigger wheel wells make the 32s look quite small! The 5 speed feels good, though I think the clutch may need a bleed, or one of the cylinders is failing. Pedal engagement is very close to the floor and reverse grinds at times.

    Sadly the brakes are terrible. I tried a fluid flush, but couldn't get the RR bleeder screw loose. So a wheel cylinder is definitely in the cards, but I feel a master cylinder may be, as well. I think a seal stuck while it was sitting and tore. No leaks, as I used a pressure bleeder, so that's good.

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  2. #77 Re: Project Hugs Version 4.0 
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    On my 5 speed ZJ I wad to put a slight bend in the clutch pedal to allow it to get full travel without the pedal bottoming out on the floor. After I did this the clutch engagement point moved up to a reasonable level. A previous owner did the conversion so I don't know where they sourced the clutch pedal from.
    96 ZJ 4.0 AX15 V8 axles some lift
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  3. #78 Re: Project Hugs Version 4.0 
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    Thanks for the tip. I'll check mine to see if it's hitting the floor, or not. The grinding occurs after a few shifts, notnall the time. That's why I'm a little worried about the hydraulics, which supposedly were replaced recently

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  4. #79 Re: Project Hugs Version 4.0 
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    Quote Originally Posted by Gearjammer View Post
    On my 5 speed ZJ I wad to put a slight bend in the clutch pedal to allow it to get full travel without the pedal bottoming out on the floor. After I did this the clutch engagement point moved up to a reasonable level. A previous owner did the conversion so I don't know where they sourced the clutch pedal from.
    Do you have any pics of your pedal setup? Mine is, indeed, hitting the floor. But looking at things it almost looks like the XJ pedals are too long. Now, that wouldn't totally fix the issue, as the bend in the pedal has left an indent in the carpet, but it may help. If I do the clutch I'll want to adjust the brake pedal, too. Otherwise they'll be really goofy to each other. I may still try a simple bleeding of the hydraulics first.

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  5. #80 Re: Project Hugs Version 4.0 
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    Oh, and a rough measurement in my uneven driveway shows close to 3" of gained clearance at the rocker panel vs the factory pinch weld. I'll have to get it on an even surface to get an accurate measurement.

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  6. #81 Re: Project Hugs Version 4.0 
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    New wheel cylinder on hand and I hope to be installing it this afternoon and bleed the brakes and clutch. Also got a new shift knob off Ebay that's not going to be as cold as the aluminum ball the swap came with. And on the note of cold, I dug into the heated seat wiring and think I can make it work with another switched 12V signal on the K-Bus circuit after testing the signal on my current BMW.

    I also saved all the side cladding, though I haven't put it back on, yet. One or two of the mounting brackets is broken, so I'll have to make a trip to the junkyard and see if I can find replacements. I wasn't sure I wanted to reuse it, but I really think it makes the look. Once the other side is done it will time for a paint update and I'm really leaning towards a desert tan with the cladding and bumpers blacked out. I've got a few other appearance tricks up my sleeve to make it stand out from the crowd.

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    Last edited by Yjsaabman717; 01-26-2020 at 01:27 PM.
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  7. #82 Re: Project Hugs Version 4.0 
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    Well new wheel cylinder is in, and the line on that side of the axle has been replaced, too. The nuts came free from the block and wheel cylinder, but wouldn't spin on the line. The pedal pumps up a bit, now, but still feels crappy. Makes me hopeful I can just bleed it out better and get my pedal back. The right rear was a bit loose on the adjustment, also, so I'll be checking the left side, because that could be part of the issue, as well. I did not get a chance to bleed to clutch today, though.

    Oth, I got the heated seats working today! Spent some down time at work this past week doing some research and figured out it's a pulsed 12V single wire Bus to wake it up. So I probed that line on my current BMW and found kt to mostly be a constant 12V with very little pulse. So I stuck the bare wire into the switched 12V and checked it out, victory! A solid 12V wakes it up and I have functioning seat heaters!

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  8. #83 Re: Project Hugs Version 4.0 
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    Quote Originally Posted by Yjsaabman717 View Post
    Do you have any pics of your pedal setup?
    Here's a couple pic's of what I've got. It looks like my clutch pedal is hitting the carpet when I shift too, I don't have issues with shifting anymore though.




    96 ZJ 4.0 AX15 V8 axles some lift
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  9. #84 Re: Project Hugs Version 4.0 
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    Well yours definitely isn't an XJ pedal setup! Thanks for the pics. I really think mine just needs a good bleeding after being moved all around while it was out of the vehicle. A couple of pumps of the pedal seems to guarantee no grinding.

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