Thread: Project Hugs Version 4.0

Page 3 of 3 FirstFirst 123
Results 51 to 68 of 68
  1. #51 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Thanks. Even though this thing is a bit crusty around the edges I still want to do things right. It still progressing slowly, but I should get some more time to work on it next weekend.

    Sent from my SAMSUNG-SM-G930A using Tapatalk
    Reply With Quote  
     

  2. #52 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Made some progress on the swap today. Decided to focus on that and if I need to drive it can throw a fender and bumpers back on quickly. This post and those following will be picture heavy as I really want to document the process I'm using really well for future reference.

    Auto shifter, cable, and shift interlock are all out. After drilling the 4 spot welds there is still a weld at the front of the lower portion of the shifter bracket. I just worked it back and forth until it broke, it didn't take much. This is definitely somewhere it would be nice to have the correct part from a donor 5 speed. It looks like I will need to cut the plate out at the top of the recess, meaning the bigger circle, for the shifter to clear right.




    Next the brake pedal came out and got lined up next to the XJ pedal cluster. There was a small bracket bolted to the clutch side of the XJ cluster, but more on that later. Once I had the XJ cluster marked I cut off the excess and welded on a new piece of 3/16" plate to make a new top. With some careful eyeballing with a straight edge I even nailed the top mounting hole.







    And here is that extra little bracket. It actually runs to the firewall and backs up the clutch master cylinder. Definitely a piece I will want to be using. Sadly, as I've read, the XJ cluster doesn't line up with the ZJ's existing holes. Clever Chrysler used the clutch master mounting hole to mount the TCM to the firewall, though! Looks like I'll be bolting the block off back in.


    The ZJ brake light switch does not fit the XJ cluster. However, I found an extra harness tucked up under the dash that the XJ one plugs right into. Not sure if it will work right, but I'll figure it out. Battery is disconnected right now.


    And finally a pic of the pedals installed.


    Sent from my SAMSUNG-SM-G930A using Tapatalk
    Last edited by Yjsaabman717; 08-24-2019 at 05:28 PM.
    Reply With Quote  
     

  3. #53 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Finally got to make some more progress today.

    My goal was to get the master cylinder mounting squared away today. The support plate has a stud pressed into it, so I made a small partial of the bracket out of some tin to locate the top hole. Then I made a card template of the master cylinder and marked it all out on the firewall. I pulled the pedal cluster back out to make some more room, but my cordless drill is just a hair too big to fit up in there right. My right angle drill is at work, so maybe next weekend. I do have a 1-1/2" hole saw that's going to be great for the hole for the body of the MC. You can see the overlap with the hole for the factory ZJ clutch hydraulics, I hope that doesn't cause too much issue.


    Next up was to pull the trans shifter and dry fit the trans to confirm the shifter location. Auto flex plate is now gone, and I pulled the trans cooler lines and the TV cable while I was at it. Trans fits as it should and the shifter should fall right where I thought it would.



    So back to working on the wheel openings. I did some final shaping of the flat insert panel at the rear door opening and worked on finishing up some of the welding back there.





    Sent from my SAMSUNG-SM-G930A using Tapatalk
    Last edited by Yjsaabman717; 09-08-2019 at 11:25 PM.
    Reply With Quote  
     

  4. #54 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Another weekend lacking in time. And this month is busy overall. I hope I can get this thing put together before I need it. Got the holes mostly drilled for the MC today. The hole saw I have has a fixed pilot bit for wood. I tried using another bit the same size, but the damned thing walked and I didn't realize it in the tight space under the dash. So I opened it up as large as I could with a step bit and will have to finish it up with a carbide burr, it looks like.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  5. #55 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Got the clutch master center hole opened up to the final size today. Test fit the master and the reinforcement plate and all is well. Looks like the pedal cluster has gone in for the final time. I'll make a plate that goes behind the clutch MC mounting and covers the pre-punched holes in the early body. I think I can remove the mounting plate from the TCM and use it to help secure the new block off plate. I'll use some bulk gasket material I have around to help seal it all.

    Nest steps include cutting the plate for the shifter, grabbing the pilot bearing and CPS, and getting the flywheel surfaced so I can install the trans. I'm anticipating a shifter modification to keep it out of the dash, but until the trans is in I can't be sure.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  6. #56 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Got back on the rocker replacement and wheel arches today. I didn't open up the front as big as the rear, I just don't think the front lends itself as well with all that's going on. I did still roll the edge to keep some structure and give it a finished look. I'm definitely wishing I had 2x6 vs the 2x4 I have. There's a slight gap to the floor when the 2x4 is where I want it with the doors. Fortunately i have some 1/8" angle lying around that I think will work well to fill the gap and the difference between the thinner metal of the body and the 3/16" wall of the new rocker. I plan to put the vertical edge against the inner rocker/floor to help distribute the load better. It's not attached, yet, but I have it cut to length, test fit, and the ends cut @ a 45 and ready to be capped.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  7. #57 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Got the ends of the rocker capped last weekend. Heading to the junkyard Saturday to source a t-case and to check out some driveshaft options.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  8. #58 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Well, I went to the junkyard under-tooled for the first time in a while. I also noticed there are two different output shaft styles. My 94 ZJ has the same style my 95 YJ had with the long tail housing and shrouded output shaft.

    https://images.app.goo.gl/xGjgiW8CuViR9GL4A

    All the ones in the junkyard were 96 or newer and had an exposed output shaft with a boot on the slip yoke. I may have to go with the newer style (though it appears to be an inch or so longer) and the rear shaft to match it.

    https://images.app.goo.gl/mRtt1yi77fhGXPZ47

    There was one XJ with an AX15 there, though. I briught home the front driveshaft from that as it's almost 2" shorter than the original front driveshaft. Between the shorter length, the low vs high pinion axle housing, and the budget boost I think it will work well.

    Sent from my SM-G970U using Tapatalk
    Last edited by Yjsaabman717; 10-26-2019 at 04:46 PM.
    Reply With Quote  
     

  9. #59 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Got some rocker work done today. The gap filler/reinforcement section has been prepped and is partially welded in. As usual it took at least three times as long as I had wanted, but it feels good to make progress. I was ignoring the waning light and pushing forward until I ran out of welding wire! D'oh! I had really hoped to have the rocker at least tacked in place today. I need to finish the reinforcement angle welding first before it gets covered up. The rest I'll finish inside at work once it drives.

    (Ok, I'm trying to use the smaller pic size as an upload to help the desk/laptop users, but it really kills the quality. Last pic @ medium upload size.)

    Sent from my SM-G970U using Tapatalk
    Last edited by Yjsaabman717; 11-09-2019 at 06:07 PM.
    Reply With Quote  
     

  10. #60 Re: Project Hugs Version 4.0 
    Pinch Yo Sack Pimp MallCrawlin Vendor
    Staff
    Kraqa's Avatar
    Join Date
    Jun 2004
    Location
    Langley, BC
    Posts
    4,260
    Rep Power
    122
    awesome detail. Keep the pics flowing.
    EPIC POLYMER RACING
    Toyo Tires Offroad Race Team | EMF Rod Ends | Big Country Customs | Mulitia Muffler | VancouverWaterjet.com | Epic Polymer
    EPIC POLYMER RACING ULTRA 4 Buggy Build WJ Grand Cherokee
    Reply With Quote  
     

  11. #61 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Today saw no actual work but many accomplishments. Flywheel has been resurfaced, welding wire has been ordered for delivery tomorrow, and a transfer case has been lined up for pickup Saturday afternoon. Found one with 104K miles, already pulled, walk up and plunk down the same cash as the junkyard only 30 miles away. Sold! Especially with less than half the mileage of most of the stuff at the u-pull-it yards.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  12. #62 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    And today saw less work than anticipated. Clutch and flywheel are in along with the pilot bearing. That's as far as I got with the trans install because the clutch fork retaining clip is broken and I couldn't get one. I did get the trans wiring sorted a bit a singled out what I need (reverse switch wiring and P/N switch wiring) and tied the rest out of the way. I also go the VSS and 4wd switches swapped over to the new t-case and the AX15 trans bracket trimmed up and the ZJ mount bolted to it. The thread engagement is less than desirable, though, so I may take it into work and try to knock the short studs out of the bracket to use the longer bolts from the ZJ. A new clutch fork retaining clip is ordered and should be here by mid week. I also forgot the bring home the clutch alignment tool that's been sitting on my tool box for over a month. Fortunately I've made do before and a deep socket with some masking tape wrapped arpund one end filled the void for me.

    I also made no progress on the rocker replacement today because I realized my cheap ass Harbor Freight helmet has stopped auto darkening. Last time I had brought home a better helmet I have from work. Looks like time to upgrade at home!

    Next weekend I hope to stop by the 'yard after work and grand a rear driveshaft to match the later t-case. Then I should be able to make some progress with the retaining clip on hand.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  13. #63 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Well, the weather pulled a surprise this morning what was supposed to be rain turned into snow. It is supposed to be over around noon so hopefully I can still get the trans and such hung in the Jeep today. This pic is actually a bit deceiving as the Jeep and its spot are the least snowy on my property.

    I did stop at the junkyard and grab a rear driveshaft yesterday and the clutch fork clip arrived Thursday.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  14. #64 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Fortunately the snow didn't last long and the sun came out and dried things up a good bit. Cold I can prepare for, but cold and wet I'm not big on.


    XJ driveshaft was a waste, it's much too short. All I really needed was the boot to the later style output flange.



    The block off plate to go between the master cylinder and the firewall that will cover the original master cylinder hole.



    I just used some ultra black rtv to fill the hole in the shifter cable grommet and will stick it back into the hole.



    The hole for the shifter turned out to be spot on.



    The shifter clears pretty well, though it contacts the console support in the forward gears. I made need to modify the shifter a bit to install everything.



    Master cylinder and block off plate installed. I used the bracket from the trans module that held the original block off and trimmed it to fit around the master cyl and support bracket.





    Trans and t-case mounted and ready. Clutch slave installed and clutch action feels good. First install of the crossmember had me worried, it was about 1" off. Then I noticed the other notch for the front driveshaft and flipped it around and all was well. Starter is also in and ready to go.

    Sent from my SM-G970U using Tapatalk
    Last edited by Yjsaabman717; 11-24-2019 at 07:16 PM.
    Reply With Quote  
     

  15. #65 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Got the rocker welded on along the top today. Still need to weld it along the bottom, but it's on there! I will go back over the joints with some seam sealer once it's fully welded.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  16. #66 Re: Project Hugs Version 4.0 
    Caucasian Sensation Staff ELLLLLIOTTTTT's Avatar
    Join Date
    Sep 2004
    Location
    San Diego
    Posts
    4,031
    Rep Power
    173
    This is an awesome thread. Glad to see some ZJ preservation!
    Ban Cowboy63b Fan Club Member #1
    Reply With Quote  
     

  17. #67 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Quote Originally Posted by ELLLLLIOTTTTT View Post
    This is an awesome thread. Glad to see some ZJ preservation!
    Thanks, man. I have to keep going to the junkyard to see the really bad ones to help keep me motivated on mine! Lol!

    Does anyone on here follow the Jeep guy on Jalopnik? He's actually recently located two factory 5 speed ZJs! One is rotted to death, the other seems to be pretty clean, though well worn.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

  18. #68 Re: Project Hugs Version 4.0 
    Member
    Join Date
    Feb 2016
    Location
    E-town PA
    Posts
    198
    Rep Power
    17
    Well, not much to show, but progress was made today. I installed the crank sensor so I won't be pissed and scratching head when I try to start it.

    I looked into my brake pedal issue, today. The issue is that the pedal doesn't contact the brake light switch. I don't see any adjustment on the pushrod, unfortunately. I was hoping to just adjust the pedal height a bit and get it to contact. So I checked a few options and the gap is pretty much exactly the same as the thickness of the old brake pedal, so I cut a chunk out and will weld that to the XJ pedal to make up the difference. Not looking forward to welding under the dash, but I also don't want tonpull the damned pedal cluster again.

    I also looked at the t-case shifter. The XJ bracket bolts to the t-case/trans joint and winds up about 1" shy of the ZJ bracket on the body. Working smarter I checked the thread size/pitch of the t-case studs and ordered up some stainless coupler nuts that are about 1-1/8" long that I can spin onto the end of the stud and then bolt the XJ bracket to. Should work perfectly and be an easy install. That's holding up the installation of the front driveshaft.

    I also test fit the rear driveshaft. Ever so slightly too short, maybe 2". I can wiggle the yoke on the output shaft with the u-joint seated in the rear, so I know it will cause a vibration goung down the road. Plus it would likely pull apart once the rear suspension drooped. I double checked the yokes between the XJ shaft I grabbed from the 'yard and the ZJ shaft. There's a tiny bit more length on the XJ yoke, though not enough to make it worth swapping over. I also noticed the XJ yoke allows more angularity tnan the ZJ yoke, so I think I will use the XJ shaft in the end. It's just over 4" shorter than the ZJ shaft, so I'll have it lengthened by 6" and it should be just right. I also hatched the plan to try to sell the ZJ shaft as a bolt-in solution for an XJ with a tall lift.

    Sent from my SM-G970U using Tapatalk
    Reply With Quote  
     

Page 3 of 3 FirstFirst 123
Thread Information
Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Posting Permissions
  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •