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4.3LXJ
10-09-2009, 01:48 AM
I am finally getting enough of this install done that I am ready to start posting on the install. When I set out to build my XJ, I wanted a vehicle that would be good as a daily driver and awesome on trails, sand, snow, rocks and mud. That is a tall order. I wheel in all those situations, and travel many mile sometimes to get there. That means I need good highway gears. One of the reasons I chose the 4.3L V6 is that I wanted to retain 6 cylinder milage. I will be putting some extra horsepower in the engine at a later date, somewhere around 320 SNOG LEGAL ponies under the hood. This build was somewhat preparatory for that event. But if I retain highway gears, then to gain good off road capability I need some real deep gears in the transfer case and transmission. The transmission is a 4L60E that I rebuilt with all the heavy duty stuff you need to make it reliable for big horsepower. I got to measuring and determined that since the engine and transmission are forward of the 4.0L/AW4 position, I could fit an Atlas 4 speed in there and accomplish what I wanted. The other choice would have been a Stack 3 speed.

So starting with the engine out, I did a tranny repair and built a new exhaust system with 50 state legal headers and a 2 1/4" Y pipe feeding a three inch cat and muffler.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0151.jpg


http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0152.jpg

At the same time, I wanted to clock the transfer case. With a 231 this would not be a problem since they only weigh 63# But the Atlas weighs in at over 175#. I just didn't feel like pushing it up a half dozen times to determine its position and change the stud position several times.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0166.jpg

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0167.jpg

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0165.jpg

And of course I had a little help with this project.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0147.jpg

So I filled it with oil and put it up. I had to hit the floor boards a few times with the big hammer to clear the rear shift rail guides. But since it is under the drivers seat it is completely unnoticeable.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0182.jpg

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0183.jpg

One thing you will notice is that there is some really tall and weird looking shift linkage. The folks at Advance adapters seem to think that these things only go into fully dedicated trail rigs without consoles. I wanted to retain the factory console and have it all look nice. I should be done with it Sunday and I will post more on that later.

COSXJFAN
10-09-2009, 08:33 AM
Man, that is a nice set up, except for the Atlas case!! I tell you what, send that piece of junk my way, and I'll get rid of it for you!!:driving:

kryptonitexj
10-09-2009, 09:04 AM
Great build. The 4.3 is identical to the 5.7 minus 2 cylinders it has great power potential. the 4L60E doesn't have the greatest rep. for durability. But with a LARGE fluid cooler you might be ok. What up grades have you done to the tranny? I look forward to watching this build keep it going. And great choice on the atlas I wish I had the money to get one.

4.3LXJ
10-09-2009, 09:54 AM
Great build. The 4.3 is identical to the 5.7 minus 2 cylinders it has great power potential. the 4L60E doesn't have the greatest rep. for durability. But with a LARGE fluid cooler you might be ok. What up grades have you done to the tranny? I look forward to watching this build keep it going. And great choice on the atlas I wish I had the money to get one.

I got a kit from Summit Racing that had kevlar bands and heavy duty clutches. Then the tail shaft, a known weak point in them is from Advance Adapters and is much heavier that stock. There is a thingy, I don't know what it is called that looks like a tall crown that holds three of the planetaries that I upgraded at the local tranny shop. Then I am running Redline high temp synthetic oil. the coolling set up is for another thread. We'll do that later.

4.3LXJ
10-09-2009, 09:56 AM
Man, that is a nice set up, except for the Atlas case!! I tell you what, send that piece of junk my way, and I'll get rid of it for you!!:driving:

:smiley-gen165:And make me go back to my 231? Besides it won't fit unless you move your tranny forward.

COSXJFAN
10-09-2009, 10:52 AM
I would NEVER think of putting that P.O.S. in my XJ!! (SARCASM!!)

I was going to...UHHMM...recycle the aluminum, that's it yeah!!:smiley-gen165:


LOL!!! Jealousy is a BIIAATCH!!

Mudderoy
10-09-2009, 11:15 AM
So how do you replace a NP231/242 with an Atlas? Fab it in?

alwaysxj
10-09-2009, 11:57 AM
looks good. how is the trany temp going to be with that header going under the jeep right next to the trany is in not going to get to hot?

4.3LXJ
10-09-2009, 01:55 PM
I would NEVER think of putting that P.O.S. in my XJ!! (SARCASM!!)

I was going to...UHHMM...recycle the aluminum, that's it yeah!!:smiley-gen165:


LOL!!! Jealousy is a BIIAATCH!!

:camera:I will give you the going scrap price for one. We'll put it in my son's YJ.:D

4.3LXJ
10-09-2009, 08:22 PM
So how do you replace a NP231/242 with an Atlas? Fab it in?

In a way, there is a lot of work that has to be done. In reality, unless you have done a chevy conversion, or you have the shorter AX 15, you can't put the 4 speed in without hacking up the floor boards. But you can put the two speed in. if you want multiple speeds, the Stack 3 speed will fit behind the AW4.

As far as bolting up the tcase, that was not hard. I had to shorten the output shaft a little because it was too long for the input. The hardest part has ben the linkage. I have spent weeks on it so that it will blend with the console and look almost factory.

4.3LXJ
10-09-2009, 08:24 PM
looks good. how is the trany temp going to be with that header going under the jeep right next to the trany is in not going to get to hot?

Currently it is wrapped. The deep pan is also finned on the bottom and I have a killer tranny cooler on it, but that will be for another post. Also, I have the lock up on a thumb switch, which you will see in the next set of pics. I will be able to use the auto like a standard tranny with the deep gears and let it idle its way through with very little heat buildup.

BlueXJ
10-09-2009, 10:33 PM
Looking forward to more pics. Have you got any with the linkage alterations? That would be the most interesting to me.

4.3LXJ
10-09-2009, 10:37 PM
Looking forward to more pics. Have you got any with the linkage alterations? That would be the most interesting to me.

You have to wait. I will install the console Sunday. Then I will show the rest of the pics

4.3LXJ
10-10-2009, 07:07 PM
Little further update. I took some more pics today, but I will finish the console tomorrow.

I picked up a handy little addition. This disc parking brake is from and outfit called Parts Mike. It turns out they are just a couple of miles from my boys in someplace you never heard of. Anyway, I dropped in to visit and had a good tome with these old boys. They have been at this longer than I have and have a couple of real nice rigs. The TJ has the same drive train I do, basically. 3.8L supercharged Buick V6, 4L60E and the same Atlas 4 speed. He said he really pisses everybody off following him while idling down hill in the slow gears at Moab. LOL

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0248.jpg

Here it is installed.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0266.jpg

I said the linkage gave me fits. I did not like the stuff that came from AA because it would destroy the console. I happen to like the console, and my wife would hate the way it looks now. Beauty she says, beauty.... So I fabbed up this set of shifters to bolt into the tunnel the same way the stock one does.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0260.jpg

And here is what it looks like installed

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0261.jpg

And under neath.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0264.jpg

Tomarrow I will finish the console and do what my wife says for a change. Beauty....

4.3LXJ
10-11-2009, 08:38 PM
Well, I finally got the console in. There are a couple of details to take care of like the wires of the thumb switch, but that will be for another day.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0268.jpg

COSXJFAN
10-11-2009, 09:23 PM
Nice work!!!!

4.3LXJ
10-11-2009, 09:34 PM
Many thanks. I'm looking forward in a few days to having it move under its own power again.

4.3LXJ
10-12-2009, 01:27 AM
So how do you replace a NP231/242 with an Atlas? Fab it in?

It will bolt on the back of an Aw4. But you would have to modify the floor board under the driver seat.

Mudderoy
10-12-2009, 02:40 AM
Hopefully you can do some video of your rebuilt rig in action. Very interesting build. All new stuff to me.

COSXJFAN
10-12-2009, 12:36 PM
Man, I'm really looking forward to seeing this thing when you are done!! Correct me if I'm wrong here, but haven't you had this thing o the road for awhile?? Are these just some "new mods" you are working on here??

4.3LXJ
10-12-2009, 05:15 PM
Man, I'm really looking forward to seeing this thing when you are done!! Correct me if I'm wrong here, but haven't you had this thing o the road for awhile?? Are these just some "new mods" you are working on here??

Sort of. Redoing some old ones, making them better. Taking care of an over heating issue, preparing to add more horsepower to the engine, fixed a short in the tranny, and of course the transfer case. So yes I have been doing lots of things to it. After this I will drive it awhile and prepare for the next phase. Rear coils, new axles and lockers. A paint job down the road.

4.3LXJ
10-20-2009, 09:35 PM
I finally got to finish the tcase install. I finished the parking brake linkage and installed it. So far, it works and looks seamless in the console because the brake handle is in the stock position and works exactly like it did on the drum brakes.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0267.jpg

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0269.jpg

I used the stock shifter and turned the bottom boot around. I welded a couple of tabs on the front of the parking brake in front of where the rod used to attach. Sorry I don't have a better pic of that, I thought I took one, but you can see the shiny metal in the pic above. I bent the stock rod, cut it and rethreaded it to 5/16X24 thread to fit the clevis.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0272.jpg

The big brown truck came today and gave the jeep another woody:rotfl2: I mean Tom Woods drive shaft. Here it is mounted . You can see the rod from the parking brake linkage.

A little welding on the exhaust and some wiring and I will start it up again. Hoohah!

COSXJFAN
10-21-2009, 12:37 PM
That is a trick set up. That would eliminate the issue with the e brake on a disc conversion as well!! Nice work, as usual 4.3!!

Mudderoy
10-21-2009, 12:42 PM
That is a trick set up. That would eliminate the issue with the e brake on a disc conversion as well!! Nice work, as usual 4.3!!

Yeah, just don't drop the rear drive shaft and you'll have an emergency brake.

COSXJFAN
10-21-2009, 12:45 PM
I'm planning on doing a disc conversion soon, and I need to figure out which one would be best!! I'm leaning towards the ZJ swap, just for the e brake issues!!

4.3LXJ
10-21-2009, 07:33 PM
Yeah, just don't drop the rear drive shaft and you'll have an emergency brake.

You still have one. Just put it in 4WD and it will work the same.

4.3LXJ
10-21-2009, 07:35 PM
I'm planning on doing a disc conversion soon, and I need to figure out which one would be best!! I'm leaning towards the ZJ swap, just for the e brake issues!!

Cos, going to rear discs is one reason I went for this. With the axle I am going to put in, getting metric and English to match up would be a pain. This has actually saved me some money going this way, and the brake won't roll backwards.

Mudderoy
10-22-2009, 01:56 AM
You still have one. Just put it in 4WD and it will work the same.

I thought of that but then I was thinking how I would explain how that would work to my wife. :rotfl2:

I like the setup but I can see how having the emergency brake back on the axle would have benefits. Was it very expensive?

4.3LXJ
10-22-2009, 02:18 AM
it was $249. But you have to have something from Advance Adapters to hang it on. They machine a ring on the tcase and their SYE to hang it on, which allows you to clock it in any position.

Mudderoy
10-22-2009, 02:24 AM
it was $249. But you have to have something from Advance Adapters to hang it on. They machine a ring on the tcase and their SYE to hang it on, which allows you to clock it in any position.

Well it's very cool!

Jeep88
10-22-2009, 04:27 AM
how i did i work out for

COSXJFAN
10-22-2009, 08:15 AM
OK, so you're saying that it would NOT work on another type of t-case, say a 242?? You need an A.A. t-case to hang it on?:popcorn:

4.3LXJ
10-22-2009, 09:03 AM
OK, so you're saying that it would NOT work on another type of t-case, say a 242?? You need an A.A. t-case to hang it on?:popcorn:

No, to put it on a 242 you would need an Advance Adapters SYE. They come with the mounting surface ready to go.

http://i649.photobucket.com/albums/uu215/warriorsuspension/2009102014050533481_med.jpg

That ring machined on the back is where it mounts with an adjustable bar to lock it in position.

http://i649.photobucket.com/albums/uu215/warriorsuspension/IMG_0266.jpg

You can see my bar on the bottom. It is two piece and requires welding to make it permanent.

COSXJFAN
10-22-2009, 09:46 AM
Thank you sir!! I'll prolly just go with a normal disc conversion with e-brake. All I have found for the 242 is a HnT type of SYE, so that set up would not work with that.

BlueXJ
10-22-2009, 09:53 AM
I am unaware of anything but a HnT for a 242. Please correct me if someone knows of another method for that transfercase.

Mudderoy
10-22-2009, 11:58 AM
I am unaware of anything but a HnT for a 242. Please correct me if someone knows of another method for that transfercase.

Well maybe Tom Woods just does the hack and tap for you but that's the route I was going for my 242, Tom Woods. :link: (http://www.4xshaft.com/index.html)

4.3LXJ
10-22-2009, 12:22 PM
Your right. I was thinking I saw a kit for a 242, but I was mistaken.

COSXJFAN
10-22-2009, 12:26 PM
I think there was one on the market years ago, but it has been discontinued. BUMMER!!

4.3LXJ
10-22-2009, 02:13 PM
There are enough 242s around you would think there would be.

Jeep88
10-22-2009, 07:41 PM
can it work with 231np

4.3LXJ
10-22-2009, 09:56 PM
can it work with 231np

It will if you use the Advance Adapters SYE. They say they have all the bases covered.

Here is their link.

http://advanceadapters.com/product/2464/50-7906.html

Logans91XJ
11-01-2009, 03:04 PM
Dude thats a freaking sweet setup!! I live in Sac and Chico is really close to me I still have a few peeps that live there. If you ever want some pics done of your jeep hit me up.

Anyways your setup is pretty much what I would like to do.!!! Very Nice write up

4.3LXJ
11-01-2009, 05:30 PM
Thanks. Sac is not far away. We go there to shop, get a few Jeep parts once in awhile from 4 wheel parts etc. We should get together and do some wheeling. PM me if you want to get together.

Logans91XJ
11-07-2009, 12:42 PM
sounds good to me