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ZachXJ1993
10-26-2014, 06:41 PM
I GOT A JEEP!!!!! This is my First Jeep.
I picked up a 1989 MJ for next to nothing. It will be a work in progress. When I got it, it had a engine from a 90 Cherokee because the old motor was overheated as many of the old closed loop cooling Renix XJ's and MJ's do. The Head gasket took a dump. The cooling system was replaced with one from a 98 Cherokee. The swap was done well enough but the guy couldn't get it to run after the engine swap. I don't know how much time he spent messing with it but the fix was easy. But first some stuff about the Jeep.

1989 Comanche longbed 4x4
Renix 4.0
Column-Shift AW4
NP231J Transfer case
HP Dana 30 Front 3.55
Dana 35 Rear 3.55
Skyjacker(I Think) 2.5 Lift (Full Adjustable Front Control arms)


I got the Engine Running again. The Problem was in the timing. The guy who owned it before changed the spark plugs and wires. well He didn't get them back on in the right spot. So the cylinders were firing one cylinder out of correct. Once that was changed the motor came right to life. However the Starter motor is not cooperating at the moment. I think it had enough life in it to start the motor a few times but it just has run out of steam. All it does is click on the starter relay. I pulled it out and it functions right but the motor is slow and the solenoid sounds like it has gravel in it. I'm going to try and track down one I can borrow to see what's what. If that fixes it then I will go get a re-man from the parts house.

Here are a few Pictures of the The Manch.

This is what it looks like now sitting in the shop. It has the grill and driver fender off the 1990 XJ the engine came out of. The rest of the grill is there it's just not on right now.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IntheShop.jpg

Here is The Manch on the trailer coming home....
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/BringingItHome.jpg

I paid no money for The Manch. I traded the Jeep for some R/C cars that weren't getting used much. Brushless Traxxas emaxx and some other Losi and HPI cars. Lots of spare parts too. Had it all loaded into my car ready for the trade.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/TheTrade.jpg

I think it has been a fair trade.
More Updates to come.
Thanks for Viewing.
-Zach

Brasscatz
10-26-2014, 07:02 PM
Holy crap what a deal! Can't wait to see this thing all fixed up!

4.3LXJ
10-26-2014, 07:10 PM
Ok, I am jealous

Pookapotamus
10-26-2014, 07:43 PM
Ditto!

XJ Wheeler
10-26-2014, 09:09 PM
Man, definitely a trade up! I'm an rc'er but that is a sweet deal! Congrats on the new mj and what plans do you have in store for it?

Sent via messenger pigeon - i talk, he types.

ZachXJ1993
10-26-2014, 09:34 PM
Thanks for the comments guys. As for The Manch I'm currently debating on whether to keep the bed or do a flat-bed hybrid. There is some rust growing in the fenders above the rear tires and the passenger panel is smashed right in front of the rear tire. As for now I need to do a few more things to get it road worthy. There is lots of play in the front end. I need a new trackbar bushing as well as new control arm bushings. I have one more coolant leak that I have to get sorted out as well.

This is a 2-door XJ but I think I could pull something like this off.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/Endresult.jpg

Thanks again for checking out my thread.
-Zach

ZachXJ1993
10-27-2014, 12:30 AM
First off here are more pictures of The Manch...

Here is one of the interior.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_180818017.jpg

The Manch has a moon roof. Not sure if it is factory, but it is awesome!!!
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_180902390.jpg

And one of the damage on the rear passenger fender.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_180845528.jpg

One of the Renix 4.0
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181210713.jpg

Front suspension and Dana 30.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_180947473_HDR.jpg

This Dana 30 has vacuum disconect...that doesn't work. Not all the parts are there. I will probably eliminate the disconnect and do a non-disco axle shaft and plate the housing.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181235061.jpg

The Manch came complete with a Bed-O-Parts. All the stuff that wasn't installed on The Manch was in the bed getting rained on all spring, summer, and fall. So there is some oxidizing going on back there.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_180803977.jpg

Now to the fixing stuff.
I decided to go ahead and replace the starter with a re-man from the parts house. And now it starts like a dream every time.

Way down in there is the new starter.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181152812_HDR.jpg

There were a number of leaks that I have fixed, but there are a few more that need sorting out. When I started pouring coolant into the radiator it started pouring out of the side of the block. The guy had taken out the coolant temp sensor. Luckily it was laying in the toolbox with other assorted bits and pieces. I finished filling with coolant and away we went. I mounted in a new coolant puke tank that was included it The Manch's Bed-O-Parts. I used some 5/16 trans cooler line to plumb it in.

Coolant puke tank all mounted up and plumbed in...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181219890_HDR.jpg

When the engine was swapped he removed the oil filter adapter to prevent it from getting smacked or broken. Which I think was a smart move, but that broke the seal that the hard as rock rubber seals had on the block. When The Manch started the filter adapter was leaking like crazy. I replaced the seals with some new ones and cranked her down....No more leaks from here.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181104245_HDR.jpg

Here are two of the seals. They were brittle and broke just by pulling them out of the adapter.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181510397_HDR.jpg

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181518885_HDR.jpg

During the swap the AW4 trans-cooler line was kinked off and broke. It had a steady stream of ATF coming out of a crack in the hose where the crimp fitting was. So i removed the cracked section of hose and used some 3/8 metal line with some new 3/8 Trans hose and re-connected the lines. I used some fancy fuel injection hose clamps. I heard that they will not cut the hose like a traditional band hose clamp will.

In the picture the right side is the one I fixed. The left side needs it too, but it isn't leaking....Yet.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181247299_HDR.jpg

I used a tubing cutter and a flair fitting tool to get a clean cut and make sure the hose doesn't come off.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181613528_HDR.jpg

The front and rear driveshafts were in the Bed-O-Parts and the u-joints were completely seized up. I got five new joints to replace the two in the rear shaft and the one regular on the front as well as the two in the double-cardon yoke.

This is one of the better ones I pulled off The Manch.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181553877_HDR.jpg

After I got them all taken apart I used a wire wheel on my angle grinder to clean off the dirt, grease, and rust. I used a round wire brush to clean up the snap ring groves and the races where the u-joint caps go.

Here is the rear cleaned, reassembled, and installed.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181334479.jpg

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181347274_HDR.jpg


The front was more of a pain but it wasn't too bad. The problem I have now is that the splined section is seized and it wont slide. I can't install it because it is too short and i can't get it to come apart. Any ideas would be greatly appreciated.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20141026_181419232_HDR.jpg


I went for a short round-the-block drive the other night. There is lots of play in the steering due to wore out control arm bushings and a bad track bar bushing. When you turn the steering wheel the body moves a inch or two side to side in relation to the axle before the wheels start to turn. Makes for a nice fun and safe drive.... So now I'm trying to locate some replacement bushings. Only problem is that I don't know for sure if it is a Skyjacker kit or something else. Not even sure if there are bushings available. Also I noticed that kickdown didn't work. The trans shifts up fine when you start moving, and down when you slow down. But when you mash the gas it just lugs without downshifting. It might be something simple like a cable or the TPS but I haven't looked into it yet. Heater works good though.....

Here is a short video of The Manch just after we got the spark plug wires sorted out. I believe that this was the first start.

http://vid849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/First%20Running%20Video.mp4


Thanks again for reading and commenting.
Let me know if you have a solution to the problems I should try.
-Zach

XJ Wheeler
10-27-2014, 03:01 AM
Try adjusting the TV kickdown cable first for that shifting issue.

Here's the instructions.

6291

Sent via messenger pigeon - i talk, he types.

ZachXJ1993
10-27-2014, 03:48 PM
I'll give the TV cable a go after work so see if that helps. Thanks for the info.

denverd1
10-27-2014, 04:08 PM
may gently heat the splined area. Have tried any penetrants? a soak in diesel may help a bit too.

ZachXJ1993
10-31-2014, 03:58 PM
In honor of Halloween I carved this......

ZachXJ1993
01-02-2015, 03:12 AM
About time I keep working on The Manch. In the last month or so I have been debating about whether or not to sell The Manch. I would then try to find a V8 ZJ or WJ. But for now I have decided to Keep the Manch. I figured that i have about 150 bucks into it including the cost of the Jeep. So I may as well build it up a little and then wheel it. I think Eventually I would want to move into something like a WJ but not yet. The other thing that is great about the Manch is it will give me lots of opportunities to fix things. That knowledge with be really useful. I haven't done much of anything to THe Manch in a while. The weather has been a bit on the chilly side. It is however nice and warm at my computer desk when i look and sometimes drool at Jeep parts. I've bee preoccupied with a few other projects as well. I did some neat things to my car, I found a great deal on a older Honda XR400 and did some work to it too.


Here are a couple pictures of some stuff I've been doing.


I installed a rack on my car.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141115_150041714_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141115_150041714_HDR.jpg.html)


I added some flood LED's behind the grill to use as fog lights.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141119_241841529.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141119_241841529.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141127_142345018.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141127_142345018.jpg.html)


Then I figured what the heck. So I used the roof rack to mount a 40 inch Bar. It is amazing how bright it is.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141204_224435081_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141204_224435081_HDR.jpg.html)


Here are the comparison shots:
Headlights only
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141206_243351807.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141206_243351807.jpg.html)

Headlights and LED fogs
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141206_243359133.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141206_243359133.jpg.html)


Headlights, LED fogs, and 40 bar
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Braparu/IMG_20141206_243411571.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Braparu/IMG_20141206_243411571.jpg.html)


I will be outfitting The Manch with some LED Lights. I figure a 50 inch on the roof would be nice to have...



Her are a couple pictures of my XR400.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141126_195109207.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141126_195109207.jpg.html)


Hey look Twins....
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/20141129_120013.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/20141129_120013.jpg.html)


I have had XR's in the past and my biggest complaint is the forks. I feel like the standard forks aren't as good as the newer inverted fork designs. I found a guy that was parting a 99 CR500. I picked up the whole front half of the bike for a steal and ordered conversion bearings from All Balls Racing. The Swap came out great. Pardon the Messy shop;)


Before:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141220_122912327_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141220_122912327_HDR.jpg.html)


Donor Forks:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/download_20141210_203539.jpeg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/download_20141210_203539.jpeg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/download_20141210_203529.jpeg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/download_20141210_203529.jpeg.html)


All tore down:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141220_133354069.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141220_133354069.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141220_133343781_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141220_133343781_HDR.jpg.html)


CR500 Triples installed with All Balls Racing conversion bearings:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141220_171725621.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141220_171725621.jpg.html)


Mostly installed:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141220_173059619_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141220_173059619_HDR.jpg.html)


Swap Complete:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141220_180950003.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141220_180950003.jpg.html)

I melted the fender on the exhaust on the shakedown....
http://i849.photobucket.com/albums/ab52/Lil_Z_99/FO%20HUNDY/IMG_20141222_155224483_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/FO%20HUNDY/IMG_20141222_155224483_HDR.jpg.html)



Anyway enough chat and non-jeep stuff. As of now the Manch is sitting behind the shop waiting for some mid winter love.

On the list first is to get the front brakes working. The axle was also swapped from the engine donor Cherokee. And I doubt the front brakes were bled or even had fluid put in. Once The Manch can stop properly then I'll focus on the 4wd. To get all fours to spin I have to get a different front drive shaft. The one I have has a seized spline. I have tracked down several at some parts yards in the area for around $45 dollars. The factory CAD in the Dana 30 has bit the dust. I'm not even sure if the proper vacuum lines are there. So I'm going to abandon the vacuum hopes and dreams of AMC and Chrysler engineers in the 80's and install a Alloy USA perma-lock non-cable disco delete. It uses the same axle shafts but locks the two passenger side shafts together. If I do those two things it should work right.

Amazon link for Alloy USA Perma-Lock:
Amazon.com: Alloy USA 451100 Differential Permanent Cable Lock Kit: Automotive@@AMEPARAM@@http://ecx.images-amazon.com/images/I/31QORuak3PL.@@AMEPARAM@@31QORuak3PL


So there are a few leaks that need to be eliminated. There is one more coolant leak, a trans cooler line leak, and the rear main seal leaks like a stuck pig. The oil pan gasket seeps some too. I think I will end up pulling the trans and t-case to get at the rear main and the oil pan. If I cannot resolve the TV kickdown issues before then I may scrap the AW4 and put in a AX15.

There is a considerable amount of side to side slop between the body and front axle. I think I'm going to replace the trackbar with a factory unit. I would replace the bushings but I have know clue as to the MFG of the lift. I would love to use the current trackbar because it is beefy, adjustable, and uses a good sized hiem bearing on the frame side. I guess I could just measure what is left of the bushing and order something to replace it.

The trackbar is beef compared to stock...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/4b107164-a661-434a-8779-5ea3947dac61.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/4b107164-a661-434a-8779-5ea3947dac61.jpg.html)


I am still undecided on whether to keep the bed or not. I'm leaning toward a flatbed because then I can use some Cherokee rear leafs, re-drill the front spring mount and add some new shackle brackets where I want. The Manch is a long be and I would like to shorten it up to cherokee wheelbase if at all possible.

Here are a couple of MJ's with flatbeds that I like.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_6267.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_6267.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/P9120028.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/P9120028.jpg.html)


Anywho boys and girls, I have quite a bit to do on the Manch to get it ready to run. Any suggestions, questions, and comments are always Welcome. And Post up if you Ride Red....

Thanks again

-Zach

4.3LXJ
01-02-2015, 10:56 AM
Lots of worthy projects for sure. On that track bar, looks like a Rancho set up on the springs and track bar. I am sure you can replace that joint

ZachXJ1993
01-02-2015, 02:57 PM
Ok so I have some great news. I was messing around with the torch today and was able to do like denverd1 suggested. I just ran to flame up and down nice and slow untill it was uncofortable to touch with a bare hand. Then i used a 3 lbs mini sledge to drive the yoke off the spline. Worked pretty good. I have quite a bit of cleaning that has to be done on it then put in a new zirk fitting and fill it up then put under The Manch. I guess it's allways a good day when you save $50 or so bucks on parts you can re-use.

Here are the pictures.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150102_133416406.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150102_133416406.jpg.html)


Splined yoke
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150102_133518462.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150102_133518462.jpg.html)


End of the splined shaft
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150102_133540126.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150102_133540126.jpg.html)


Thanks again for the replies and for the knowledge yall have to share that makes XJTalk the best Jeep website.
-Zach

4.3LXJ
01-02-2015, 03:50 PM
Yeah that looks like it has seen some mud. After you get it together, make sure it dos not have slop in it

ZachXJ1993
01-02-2015, 03:57 PM
Will do.

bluedragon436
01-02-2015, 05:15 PM
Man that is a kick ass deal for sure.. Wish I could have found a deal like that to pick up a MJ or XJ... I got a few RC's that haven't moved in quite a while... even have the parts to get them up and going which I just picked up last year, but haven't been able to get them going for some reason... I think going flat bed, or doing a tubed bed with an integrated roll bar, spare tire mount.. Something along the lines of the that second flat bed idea pic you put up.. That was my plan had I found a decent shaped MJ to pick up instead of the the XJ I got.. Look forward to seeing the revamp/buildup of the Manch!!

ZachXJ1993
01-05-2015, 06:18 PM
I was able to get the front drive shaft back together today. It warmed up a bit outside so I could stand the cold.

I had a problem with the oil seal because the grease zirk hole was stripped out. I was going to try and locate a new oil seal, but I went a different route. I went to the local parts house and picked up a 1/4-28" zirk fitting. I drilled and tapped a new hole in the oil seal for the new zirk fitting. I used the miller to weld up the old hole. I lubed the splines and added grease after it was all put back together.


Here is the stripped insert for the factory zirk.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150105_162022358.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150105_162022358.jpg.html)


New grease fitting.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150105_162038005.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150105_162038005.jpg.html)


After welding the hole.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150105_164122070.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150105_164122070.jpg.html)


Reassembled drive shaft.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150105_164841632.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150105_164841632.jpg.html)


There isn't much play in the splines so it should work for a while.
Tomorrow the UPS man should bring my Alloy USA disco delete kit. I should have four wheel drive by the weekend....


Thanks for checking out my thread.
-Zach

ZachXJ1993
01-07-2015, 11:22 PM
I got my parts in to fix the CAD on the Dana 30.

Here is a little tease...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150107_221742622.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150107_221742622.jpg.html)


Man I sure love that feeling you get when Jeep parts come in the mail...
Should have it all together tomorrow.
-Zach

ZachXJ1993
01-09-2015, 01:14 AM
Well I would say that today was very successful. I got the 4 wheel drive working again. :D Everything went as planned and I found out more about my axle slop issues.

Lets start with the good stuff. As I showed in my last post I got the Alloy USA/Rugged Ridge perma-lock for CAD equipped Dana 30 Axles. This was a awesome buy. It was around 45 dollars on Amazon and I'm happy with the product and price. The kit came with great instructions and was super easy to install in the axle.


Here is the inside of the new shift fork housing.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_152402501.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_152402501.jpg.html)


The instructions said to use thread sealant on all the bolts and inserts. I remember a XJTalk show episode from way back when. Josh was welding new control arm brackets on his axle and Steve "4.3LXJ" said that axle housings could get quite warm while driving. So I opted for some red high-temp RTV. I put some on the housing and worked some into the threads of each bolt.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_152357425_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_152357425_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_152826534_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_152826534_HDR.jpg.html)


The next step was to remove the vacuum CAD housing, motor, and bash guard. The old one was filthy and covered in oil grease dirt mix. The vacuum hoses from the frame to axle were nowhere to be found.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_164658135_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_164658135_HDR.jpg.html)


After removing the bash guard. You can see how caked the axle is...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_170608438_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_170608438_HDR.jpg.html)


Removal is a real simple. Just take out the 4 bolts and pull straight off the axle.
NOTE: Gear oil will pour out from the cover so watch where you put yourself under the jeep. Nasty stuff....
Here is the whole unit. You have to remove the three c-clips on the shaft to remove the fork and motor.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_171451838.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_171451838.jpg.html)


I spent a minute to clean up the shift fork a bit.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_172546896_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_172546896_HDR.jpg.html)



All put together ready to go in the axle.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_173600381_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_173600381_HDR.jpg.html)


I scraped off the old gasket and cleaned up the mating surface. The new kit uses a fitted cork gasket and says not to use any other sealant. My CAD wasn't engaged so i had to turn one wheel until the shafts lined up so I could slide the lock collar over to engage the two halves.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_174124855_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_174124855_HDR.jpg.html)



All buttoned up...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_174627007_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_174627007_HDR.jpg.html)



Overall it was really simple to install on the axle.



I got my front drive shaft ready to go the other day so I installed it as well. New bolts and caps for the front and new bolts for the DC in the rear.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_160650420.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_160650420.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_164614696.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_164614696.jpg.html)


I tested the 4 high and 4 low on a snow pile. Both work well. :D It is a great feeling to get some progress going here on the Manch.



Now for some interesting finds while lying under the Manch.

I noticed one of the bolts on the trans cable bracket was loose. So I tightened it up.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/52564311-ae96-4d70-9d0b-21d8533bd9f6.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/52564311-ae96-4d70-9d0b-21d8533bd9f6.jpg.html)



The rear main seal on the 4.0 leaks pretty bad. I'm nearly 100% positive that that is where all the oil under the Manch is coming from. I had my flashlight under there looking around for things that were amiss. I was looking at gap between the trans and the oil pan and could see the rear main seal... It is obviously installed wrong. It looks like it is sticking out of the block which wont seal up too good. I guess I will fix that in the near future as well. Probably do a new oil pan gasket while I'm at it.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150108_164804057.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150108_164804057.jpg.html)



I think that I have found the culprit of the front axle slop. I had my Dad help me isolate the movement. I watched several things that I thought could be the problem while he turned the wheel back and forth. Trackbar, upper control arm bushings, steering parts, but what I saw was the drivers side lower control arm sliding in the rear mount. Right where the big bolt goes through the unit-body. Turns out that there are some adjuster bolts on the back of the control arm bracket that are loose. Not by a small amount either There is a good 1/4" of play. I can see on the side of the control arm bracket where the washer and bolt have been sliding. Oh and that bolt isn't super tight either....
I tried to tighten the adjuster bolts but they are seized up on the studs. I used some PB blaster but they still didn't budge, and when I give it more pressure I can see the studs twisting slightly. I don't want to break one off so I'll keep sousing them with PB until they break loose. I'm hopeful that if I get this tightened up it will solve the slop issues I'm having.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/d736a6fa-a36e-40c7-8bc3-e2f3ed565c69.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/d736a6fa-a36e-40c7-8bc3-e2f3ed565c69.jpg.html)



Any ideas on freeing rusted up bolts?

I'm excited about the good and bad things that I'm fixing and finding on the Manch. Stick around, there is more to come. Keep the comments and suggestions coming.
-Zach

XJ Wheeler
01-09-2015, 03:14 AM
Nice progress! I like the simplicity of the cad delete. Not much to go wrong with that!

autotech98
01-09-2015, 07:39 AM
Yeah lookin good.on the bolts id say keep soaking them and apply a little heat to the nuts. If that doesn't work you can always use a nut splitter and put new nuts on it

ZachXJ1993
01-09-2015, 11:20 PM
I got more started on the Manch tonight. I got the big bolt on the drivers lower control arm tightened up. The small adjuster nuts on the back wouldn't budge after additional soaking with PB. I will probably have to use the torch to break em free. Anyway getting the big bolt tight made a big difference in the axle slop.
I again had some help in determining where the loose parts were. I found that the slop was now pointing right at the track bar. Both the heim joint and the poly bushings where moving. I saw that the relocation bracket that mounts the track bar in the old stabilizer spot had some play in it as well. After tightening that up too I could tell that the bushings were shot. So I feeling ambitious decided to remove the track bar to see what's what. I used some PB on all the bolts and let them soak for a few minutes before attempting to break anything loose.

Part of the problem is that the holes in the mount are ovaled a bit. In the picture you can see the edge of the hole is starting to roll. I think to fix this I will get some grade 8 washers that are just smaller than the bolt and drill them so the bolt has no slop. Then weld one to each side of the existing bracket.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/696a711b-c08a-47e1-a0ac-eade9e3450e2.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/696a711b-c08a-47e1-a0ac-eade9e3450e2.jpg.html)



It took some time but I did manage to get the track bar out of the Manch.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_192529691_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_192529691_HDR.jpg.html)



Again I used the PB Blaster to penetrate the jam nut. Once it was free the joint came off without too much effort.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_192503067_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_192503067_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_193019680.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_193019680.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_193232526.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_193232526.jpg.html)



There is some corrosion in the threads of the joint as well as in the track bar itself.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_193339848.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_193339848.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_193249851.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_193249851.jpg.html)



I took the joint apart even further and found that the hardware wasn't too messed up. I cleaned the hardware up so I could reuse it easily.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_193540524.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_193540524.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_194446309.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_194446309.jpg.html)



When the Track bar was in on the Manch the joint sat at a angle and it wore that way. There is not much play in the joint but it is enough to be a problem. The poly bushings at the other end are a little worse for wear. They are hard as rocks, brittle, and cracked in several places. Overall not good. The sleeve is in rough shape too. It like the mount is ovaled.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_192455463.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_192455463.jpg.html)



I used a vice to press out the sleeve, then used a hammer and punch to remove the bushings.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_195418574_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_195418574_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150109_195408559.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150109_195408559.jpg.html)



There is a part number on the bushings "MO2888" which I found was a Skyjacker PN. So I would assume that the lift is a SJ. Should make finding other parts easier. I found a link that showed a parts list and install instructions for the trackbar kit.
http://skyjacker.com/Instructions/JEEP/TBA80.pdf
This gave me the part numbers I need to get the track bar rebuilt and ready to go. The 3/4" RH rod end is available from several online stores but is around 60 dollars. The bushings and sleeve are about 6 dollars each. I found other sites that sell the same size rod end but for much cheaper.
I really like these from Ruff Stuff Specialties
http://www.ruffstuffspecialties.com/catalog/34RE.html
I'm really impressed with their products. I helped install a full set of adjustable lowers on a TJ and they are Massive!! Great quality products from what I have seen, and the price sounds right.

I'm fairly certain that after I get the track bar sorted out then the slop and play will be eliminated. Fingers crossed:pray:

I'm headed down to Florida next week and will be gone for a couple weeks. I know I wont get the track bar buttoned up by then so please be patient. I will get back to business when I get back in town.

Thanks again for the comments.
-Zach

ZachXJ1993
01-24-2015, 12:51 PM
Quick update folks. I'm not home yet from Florida, but I went ahead and ordered the track bar bushings and rod end so the parts would only be a day out when I get home.
Anyway I get it back together when I get home and we should be back in business.

-Zach

bluedragon436
01-24-2015, 06:10 PM
Progress is progress... tackling the problems one by one as they come along is a good and smart way to handle it... Doing similar with my 97 XJ I got..

ZachXJ1993
01-28-2015, 09:13 PM
Well I have safely returned from Florida. Nice place though. Weather was great and the sunshine was awesome. Anyway like I said in my last post I ordered the parts to get the trackbar buttoned back up. Today the UPS man brought me a package from Summit Racing....


Two new bushings and a new sleeve.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150128_181103710.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150128_181103710.jpg.html)


Got one slipped in....
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150128_181225634.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150128_181225634.jpg.html)



Two...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150128_181411856.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150128_181411856.jpg.html)



And the sleeve...
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150128_181953489.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150128_181953489.jpg.html)


The tracking # says the Ruff Stuff rod-end will be here tomorrow. I will get that put back together and then do some work on the axle where the track bar mounts. I think finding some washers that are super tight fit on the bolt should make a difference in the slop, and hopefully prevent any further damage.


Ya I feel like the Manch has a never ending list of problems to tackle. I sometimes wonder what I've got myself into....

Progress is progress... tackling the problems one by one as they come along is a good and smart way to handle it... Doing similar with my 97 XJ I got..

-Zach

bluedragon436
01-28-2015, 09:18 PM
Nice.. that is a project I'm about to have to do to my TB I have waiting to go into my 97.. I just have to work the old cut off bolt & torn up bushings and sleeve..

Just keep your head up and keep going with the build, and she'll come together and you'll be enjoying her before you know it... and have peace of mind knowing it's all good to go..

ZachXJ1993
02-01-2015, 10:56 PM
Great success!!!!!! I got the track bar re installed and the slop is gone!!!!:D

It was quite a process to get it fixed. I had help from my cousin. It's nice to have a extra set of hands.

I started by putting the track bar itself back together. I got the 3/4" rod end from Ruff Stuff Specialties.
Old versus new. They are nearly identical, however the Ruff Stuff has a bit more material around the ball.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_183505434_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_183505434_HDR.jpg.html)



I test fitted the misalignment spacers and the taper-sleeve. Everything fit like it should.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_183654712_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_183654712_HDR.jpg.html)



The rod end looks nice in there...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_184500795_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_184500795_HDR.jpg.html)



Here is a good picture to compare the Old and New.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/TB%20new%20VS%20old.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/TB%20new%20VS%20old.jpg.html)



Now for the fun part. I had to figure out how to keep the track bar from making the holes in the mount. I went to the parts house here in town and found what I needed. I bought a 1/2" Grade 8 bolt that was 3.5" long. I wanted it to have a long shoulder so the track bar wouldn't wear down the threads. I also got four 7/16" washers, two 1/2" washers, and a grade 8 nut.
Here is the old bolt and nut and the new ones...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/10646bb7-4c94-4e2f-9d88-2a81558d0419_1.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/10646bb7-4c94-4e2f-9d88-2a81558d0419_1.jpg.html)



I took the new hardware and put it together to see how everything would fit.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_191750900_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_191750900_HDR.jpg.html)



I then moved the steering stabilizer bracket out of the way.
This gives a good look at how ovalled and rolled the mount holes are.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/ea788eaa-5461-48d4-8e1a-03facc4d1b04.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/ea788eaa-5461-48d4-8e1a-03facc4d1b04.jpg.html)



I broke out the angle grinders to clean up the bracket for welding.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_192758704_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_192758704_HDR.jpg.html)



Took a minute but it won't weld if it's dirty.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_193919684_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_193919684_HDR.jpg.html)

It was super tight fit even with a 1/4" die-grinder, but there was still some rust in there. Not enough room with the spring in the way.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_195049601_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_195049601_HDR.jpg.html)



I mocked up the bolt and 7/16" washers without the 1/2" washers. I used the old bushing and sleeve to keep things centered and make sure the new bushings would fit after welding.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/5ff56f9e-0366-4f42-ad47-dc9dbbb024bb.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/5ff56f9e-0366-4f42-ad47-dc9dbbb024bb.jpg.html)


I welded the front side first with the bushing and bolt in place. I don't make the best looking welds but there is good penetration into the washers and the bracket.
This is after I finished both sides.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/473fe4cd-b9f1-4d84-bed8-efd4f0f2acc2.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/473fe4cd-b9f1-4d84-bed8-efd4f0f2acc2.jpg.html)



In order to clean up and weld the bracket on the back of the axle I removed the coil spring. Also ended up removing the shock absorber to give the axle enough droop to remove the spring. These coil compressors are super handy for projects like this.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_202809299.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_202809299.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_203913745.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_203913745.jpg.html)



This is the back side of the mounting bracket all welded up.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_205341710.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_205341710.jpg.html)



Then it was just reassembly. I used the 1/2" washer to give lots of surface pressure on the mount.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_210724599_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_210724599_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_210739852_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_210739852_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_210755636_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_210755636_HDR.jpg.html)



I put the sway bar link back in as well to tie the adapter bracket to the axle in two spots.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_211013285_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_211013285_HDR.jpg.html)



I put the coil spring back in and re-mounted the shock absorber.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_212327039_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_212327039_HDR.jpg.html)



Then finally re-installed the frame side of the track bar and cranked it down.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_215602467_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_215602467_HDR.jpg.html)



All back together....

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150130_215617000.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150130_215617000.jpg.html)



Now when you turn the steering wheel the body doesn't move side to side. Then wheels just turn like they are supposed to. I'm super pleased with how this has turned out.
I have discovered something however. The power steering box moves ever so slightly when you steer. Not sure if it is supposed to move a bit or if it needs tightened up as well.

However I did take it for a quick spin and the steering was pretty good. There is a bit of play in the steering wheel. I think making sure the steering components are tight and aligned should help lots.


When the axle was swapped from the donor XJ the front brakes were never bled. In fact the reservoir in the brake booster is empty. So I think that will be the next project. I'm also gearing up to pull the engine and do a rear main seal, oil pan, intake/exhaust, and valve cover gaskets. While I've got it pulled I'll sort out the wiring and some vacuum stuff. Should be fun...

I'm not sure what brands of gaskets and seals I should use. Any input would be great.

Thanks again for the tips and tricks that have gotten me this far into the build.
-Zach

4.3LXJ
02-02-2015, 10:28 AM
Just a suggestion on this Zach. It looks like someone has redone that track bar mount. Normally they go under the coil at the same height as the tie rod end. If you leave it there I would suggest more beef in that mount. They can take some tremendous forces off road. I have ripped my lower mount off and had to replace the upper mount because it was toast. If you loose either mount, it is no fun

ZachXJ1993
02-02-2015, 10:36 AM
OK thanks for the input Steve. Sounds like a good idea to me. I'm wanting to eventually run a front truss. I think I will tie all the track bar mount in as well.
-Zach

XJ Wheeler
02-02-2015, 10:41 AM
I would just use Felpro for the gaskets. Easy to come by and will do the job. For the valve cover i chose to get the re-usable rubber/metal reinforced option. Its a bit more money but suppose to be great. Haven't put it on yet though.

On the steering box i would definitely check the tightness. You don't want it moving, it put stress on the frame and that area is known to crack.

Sent via messenger pigeon - i talk, he types.

XJ Wheeler
02-02-2015, 10:49 AM
Just a suggestion on this Zach. It looks like someone has redone that track bar mount. Normally they go under the coil at the same height as the tie rod end. If you leave it there I would suggest more beef in that mount. They can take some tremendous forces off road. I have ripped my lower mount off and had to replace the upper mount because it was toast. If you loose either mount, it is no fun

Yep, that's skyjackers method.

Sent via messenger pigeon - i talk, he types.

ZachXJ1993
02-02-2015, 11:28 AM
I actually ordered gaskets and seals last night. I ordered all Fel-Pro. New real main seal. New valve cover gasket. New one piece oil pan gasket and new intake/ exhaust gasket.
There was a new head gasket that came with the Manch too. Not sure if I'll do that right now though.
-Zach

ZachXJ1993
02-05-2015, 02:22 AM
Ooooo! Look what I found.....
http://i849.photobucket.com/albums/ab52/Lil_Z_99/Fred/IMG_20150204_232659450.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/Fred/IMG_20150204_232659450.jpg.html)

-Zach

ZachXJ1993
02-14-2015, 01:36 PM
So last week I called a guy up and asked about his $650 dollar XJ. There was no picture in the ad or and more info other than price and that it was a 1990 Jeep Cherokee. He said it was complete, had ran last summer, will crank, has a clean title, and he wants $450.....So my cousin, a good friend, and myself gathered our things and drug the flatbed over to his house cash in hand. It was pretty late, around 9:30 pm or so.

We were not dissapointed....

A few Specs about the Jeep:
1990 Jeep Cherokee Limited
Renix 4.0l
Aw4 4 speed auto
np242 Transfercase
Non CAD dana 30 front
Dana 35 Rear.
Not 100% sure on the gear ratio. My bet is 3.55


So while still at the guy's house we got some jumper cables out because the Jeep didn't have a battery. And as the guy said it did crank. There were a few problems that were immediately apparent.

The Fuel pressure regulator has some tiny pinholes in it and sprays the smallest stream out everywhere.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/Fuel_regulator.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/Fuel_regulator.jpg.html)


Not sure if just the reg. can be replaced, but the whole rail might be just as bad.

The main thing that I was concerned with was that the Jeep was complete, which it is.

I purchased the Jeep for parts for the Manch. The front fenders and grill are unmolested and not broken. It also has Bucket seats and a center console. I was going to use the doors as well but they are in worse shape than the ones that are already on the Manch. There are other parts that I will be scavenging off it as well. Another great thing is that the wirng and vacuum system isn't hacked up like the Manch's so I can reference it to make fixes and corrections to the Manch.

My cousin has a WJ as his daily driver, but wanted something to play around in and do crazy projects to. So I will swap the better parts off the the Cherokee to put on the Manch. Then he'll buy it off me and I'll have some cash for some late model XJ doors that are down at a salvage yard in town.

Anywho I'll get some pictures and post them up.

Thanks for reading and commenting.
-Zach

XJ Wheeler
02-14-2015, 03:57 PM
Nice deal! Works for everyone so even better.

Sent via messenger pigeon - i talk, he types.

4.3LXJ
02-14-2015, 04:13 PM
Sounds like a good find for a parts rig

autotech98
02-14-2015, 08:05 PM
Awesome strip and flip...

ZachXJ1993
02-15-2015, 12:37 AM
I took some pictures of the Popsicle. We have decided to name it that.


The body is quite straight. There are a few dents and dings here and there but nothing that a coat of paint and some elbow grease couldn't fix.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143614469.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143614469.jpg.html)



The rear passenger corner had been hit. Hence the broke taillight. Rear hatch is good though.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143547750_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143547750_HDR.jpg.html)



Other side

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143510383.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143510383.jpg.html)



Dash was pulled to replace the ignition barrel. Seats are a bit rough but I have new foam for them. Also they'll get some Coverking balistic covers.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143510383.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143510383.jpg.html)



Yes...That is the head liner... There was a yard stick that was jammed above the trim to keep the roof liner off the drivers dome.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143534344.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143534344.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143642270_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143642270_HDR.jpg.html)



And the engine bay is all put together and unmolested....

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150214_143502130.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150214_143502130.jpg.html)


Anywho Enjoy....The Popsicle
-Zach

ZachXJ1993
02-16-2015, 01:16 AM
In the last couple days I've got some good progress done on the Manch. I ended up removing the front fenders grill and A/C system. I'm trying to get it ready to take the parts off the Popsicle. I wont be adding A/C back however. I would rather have on-board air. I sorta skimped on pictures this time...It was late and I filmed the whole thing on the GoPro. I'll try my hand at editing and see what it looks like...


And so it begins....
The grill and driver side fender are off a '89 XJ that the previous owner got the engine out of. The Passenger fender is factory and has been trimmed.

I decided to start on the passenger side.
There are 4 torx bolts along the top of the fender where the hood sits. There are two bolts on the bottom of the fender where it mounts to the rocker, two between the fender and unitbody that you access from behind the door, and there are two nuts that hold the grill to the fender. There is also a hanger in the wheel well that is supposed to help keep the fender from flopping around. Both of mine were pre-unattached from the fenders.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/02a5da29-0945-44e1-99cc-fcabb7e80063.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/02a5da29-0945-44e1-99cc-fcabb7e80063.jpg.html)



So after I took out all the bolts and loosened the nut the fender came right off. I tried to remove the antenna but it was just spinning in the fender. I got it out after the fender was off the Manch.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_221524098.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_221524098.jpg.html)



And off...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_221731965.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_221731965.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_221739595_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_221739595_HDR.jpg.html)



Then repeat....

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_223114583.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_223114583.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_223122442.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_223122442.jpg.html)



Now for the grill, I'm not exactly sure what all has to be done to remove it if your Jeep is still intact. Mine however came right off after the fenders were removed. It looks like there should be about 4 or 5 bolts along the top that hold it down to the cross piece that encases the radiator. There might also be some more along the bottom but like I said on mine it was already loose/broken... Also you have to unhook the lighting harness.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_223328869_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_223328869_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150213_223322545_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150213_223322545_HDR.jpg.html)




I will post up about the A/C delete later.
-Zach

bluedragon436
02-16-2015, 05:05 AM
I know how much fun it is to take the header panel and fenders off.. especially when there are stubborn fasteners to deal with.. Looks like it is coming along Zach... and don't worry, I plan on doing the AC delete to my XJ after I get all the parts I have collected up for it installed.. so look forward to seeing how you do your OBA setup, as I've been looking at others both on here as well as other setups I can find online..

ZachXJ1993
03-25-2015, 12:21 AM
Hey it's been a while since I last posted up on here. I have been neglecting the Manch a bit.
But I have been mowing over lots of ideas on what direction to go with it. Still trying to figure it out but i'm leaning toward a v8 drivetrain swap from a 90 something Chevy because this.......



http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150324_182457651.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150324_182457651.jpg.html)



2005 Ford F-350 1 ton axles.
Front is a Dana 60 35 spline factory hubs
Rear is a Ford 10.5 35 spline full floater
4 wheel discs and 3.73 gears
front axle has trackbar and steering attached.

300 Doll hairs for both axles. Guy i got them from was going to use them on a 77 quad cab ford but went a different direction. I couldn't help pic them up for that price.

Thanks for reading
-Zach

4.3LXJ
03-25-2015, 12:38 AM
That was a good deal for sure

bluedragon436
03-25-2015, 01:16 AM
Definitely can't say I blame you for snagging that deal on those axles!! I would have definitely jumped on that deal if it presented itself as well!!

ZachXJ1993
06-01-2015, 08:23 PM
Not too much has happened on the Manch lately. I did manage to get the Bed removed. However now it wont start. It started when I moved it to the front of the shop but wouldn't start to get moved again. I'm 99% sure it is a fuel issue. it cracks off for a sec when fuel is put in the throttle body. Not sure if it is a fuel filter or the pump. The pump fires when I turn on the key, but it may be really weak.


Anyway here is the rear frame section.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150526_175834706.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150526_175834706.jpg.html)


Thanks,
Zach

JENSSEN
06-01-2015, 11:42 PM
Try grounding the tank with some booster cables to the chassis and see if it runs ,.. :rolleye0012:

ZachXJ1993
06-03-2015, 07:45 PM
I ran some cables from the tank to the frame and it started right up.
Thanks for the help,
Zach

JENSSEN
06-03-2015, 11:07 PM
I ran some cables from the tank to the frame and it started right up.
Thanks for the help,
Zach

Been there,...glad I could be of assistance,...

ZachXJ1993
06-06-2015, 03:54 PM
A buddy of mine had some ProComp 2.5" YJ Leafs laying around. I got them cheap. I have decided that in order to get the 1 ton axles under the Manch I'm going to convert the front to leaf spring. I plan on doing shackle in the back. I understand that there are plenty of drawbacks to leafs vs coils, but I'm more concerned with getting the axles under for cheap. I plan on converting the front to a crossover style steering setup. I'll have to have my Dana 60 knuckle machined to accept a high-steer arm. Also I will add anti-wrap bars to the front and rear. I'm looking for another set of YJ springs to put on the rear end. I want to shorten the wheelbase by shortening the rear 9" and add 2" to the front to help move the tires away from the cab.

Here are those springs.
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150604_203042981.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150604_203042981.jpg.html)

Thanks again,
Zach

ZachXJ1993
06-27-2015, 01:18 PM
So I have made some big decisions on the Manch. With the condition of the vacuum system and some of the other gremlins in the Renix system I decided to eliminate the issues all together.
So after doing lots of research and reading on the subject I was unsure on what I should be looking for as a engine donor. There are builds about putting a 4.7 or a 5.2 from Grand Cherokee's in but I have heard they have troublesome wiring.
I even thought about going for ultimate custom and changing everything to fit a 4bt Cummins, but that option is quite expensive and so out of reach for me right now.
Novak Adapt says that the GM tbi engines like the 4.3 or the 5.7 are great for swaps because they have low intakes and have high mounted accessories. The newer LS truck engines like the Lm7 5.3 or the Ly6 6.0 have a taller intake and lower mounted accessories. The LS engines come with lots of advantages, but also a higher cost.

So I decided to yank the Jeep drivetrain and then see what I found find that would work.


Here is after removing the radiator, wiring, hoses, and other small stuff.
Now you see it...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150610_193702332.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150610_193702332.jpg.html)


Now you don't...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150610_213628155.jpg


I have a YouTube Channel called For Brap Sake. I have several videos of various things but mostly motorcycle related stuff. I posted a video time lapse of removing the engine of the Manch. And for the shameless plug, if you like the video check out my others and like and subscribe.

Watch in HD!!
https://www.youtube.com/watch?v=_BqqpuYpVIc



I'm looking to sell the drive train as a whole. 4.0 Aw4 and 231J. I live in south East Idaho.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150610_213704537.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150610_213704537.jpg.html)


I had to find a replacement engine so I looked around and found this little Gem.

1990 GMC Sierra SLE Z71 offroad package. It is well used and has 250K on the odometer, but it was a steal. It's on the trailer because it has sketchy tires and a bad fuel pump.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150621_195753285_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150621_195753285_HDR.jpg.html)


Engine is a TBI 350 V8 with a 700r4 trans and a 241C t-case.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150621_195842220_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150621_195842220_HDR.jpg.html)


While browsing the local self pull part yard I scored a set of doors off a 2000 XJ and some seats out of a 2004 Honda Civic 2 door.
The Cherokee was in a house fire, so I need to get some parts to get them ready to bolt on. All Wiring is intact except for the mirror wires. Drivers side needs glass, trim, and a mirror. Passenger just needs trim.
I went with a set of buckets out of a car because they have low seat brackets so I will have room to make some adapters to mount to the Manch's floor.


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150615_152811656_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150615_152811656_HDR.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150616_230738114.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150616_230738114.jpg.html)


Thanks for reading and hopefully checking out my channel on YouTube. Let me know if you have and tips or suggestions.

Zach.

4.3LXJ
06-27-2015, 02:06 PM
You have your work cut out for you. Better get the big shoe horn out

Brasscatz
06-27-2015, 04:58 PM
This is going to be a very nice build!

Pookapotamus
06-27-2015, 05:32 PM
Sweet! I'm off to get some popcorn and watch this build progress!!!!!


Sent from my iPhone using Tapatalk

XJ Wheeler
06-27-2015, 06:00 PM
I like it! And use of a readily available motor so parts are plentiful.

Sent via messenger pigeon. I talk, he types.

bluedragon436
06-28-2015, 08:56 AM
Looks like a nice selection of parts to build this out of... Look forward to seeing it progress!!

ZachXJ1993
07-31-2015, 01:02 AM
I've got more progress or more like parts to put in the pile.

I was searching on craigslist and found a feller selling some Cooper STT's in 37". I gave him a call and went and picked them up.
They are 37x12.50R17. I picked up five of them. They are used but in decent shape. They have a bit more than 1/4 inch of tread in the centers. There is 3/8 or 1/2 along the sides. He ran them on his Ford Superduty and so he had some steelies that fit 8 on 170 lug pattern that will match my axles, and beacause they are 17" there is no need to grind the brake calipers. I was going to run the H1 beadlocks but this was a great deal. I ended up with 5 tires and 4 wheels for $300. Seemed fair to me...


Here is what the wheels look like. I plan to paint these Black.
Chrome doesn't belong on a Jeep.
Eventually I want to get a narrower set and do some weld on Beadlocks.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150730_230527479_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150730_230527479_HDR.jpg.html)



And the big stack of tires.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150729_092639642_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150729_092639642_HDR.jpg.html)


I'll prolly get these mounted up this weekend and then I can roll the axles around and get them under the Manch.

Thanks for reading and commenting.
Zach.

bluedragon436
07-31-2015, 03:17 AM
Yeah, I'd say that is a great deal on rims/tires!!! Can't wait to see them mounted on the MJ!!

4.3LXJ
07-31-2015, 07:21 AM
That was a good deal

ZachXJ1993
09-30-2015, 02:37 AM
So this happened this last week...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150926_171938715_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150926_171938715_HDR.jpg.html)



And some goodies from Ruff Stuff Specialties... Can you say BEEF!!!!

All the metal parts are either 1/4 or 3/8 inch thick. I'd say it was a great deal for what I got. I'm on their email list and it seems like every other week or so there is a 10% or 15% off sale. I jumped on a 15% deal a few weeks ago.
All the Parts are laser or plasma cut (not sure which) and then bent accordingly.
They didn't skimp either. The shackle hanger bushing sleeves are made of DOM instead of HERW, and have a nice machined chamfer to make bushing installation easy. All the Hardware included for the u-bolts is top notch. Can't wait to welcome myself to amateur hour and do some welding.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20150926_183518453.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20150926_183518453.jpg.html)



More Updates coming soon.

Thanks again, Zach.



Also a picture that shows the direction I want to go with the Manch.

ZachXJ1993
10-18-2015, 12:39 AM
Got some good progress on the Manch to share.... The Rear suspension is most of the way sorted out and there is just a bit more welding to be done. I had some good help today and we got lots done.

A couple nights this last week I spent some time trying to get stuff ready for today (Saturday). I wanted to get the rear suspension and axle out so that we could focus on welding and fabrication today.

The first night I started with the shocks and brake lines. I got it all apart accept for the two forward leaf spring bolts. They were a huge pain because the bolts were rusted to the metal sleeves in the bushings.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151015_230107188.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151015_230107188.jpg.html)




Then next night I got started cutting off bolt heads to get the leafs out of the frame. I got one side done then started on the other.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151016_213133263.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151016_213133263.jpg.html)



My evening of Grinding was brought to an abrupt halt when the grinder caught a good bit of the bolt and found my wrist. It cut right through my glove and split me open good. I went to the local urgent care and got stitched up. It took the doctor a while to clean all the rust, metal, and bits of grinding disk out of my wound.
Fortunately I missed all major veins and tendons, but the back of my thumb is totally numb. The doctor said that the feeling should slowly return after it heals back together. Defiantly blessed that it wasn't worse or else I might still be is surgery. 6 stitches and a tetanus shot later and at about 1 am I got home and called it a night.

Warning: Gore....


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/download_20151016_230142.jpeg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/download_20151016_230142.jpeg.html)





Now that that is out of the way I can talk about all the progress that we made today.
We started by finishing what I started last night and removed the gas tank and got the springs out the rest of the way.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_103533924.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_103533924.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_104153917.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_104153917.jpg.html)


We cut off the old leaf center bolts so that we could remove the add-a-leafs.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_110839879.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_110839879.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_110844243.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_110844243.jpg.html)


I'm moving the spring mounts forward 12 inches to shorten the wheelbase. so the old mounts had to go. The plasma cutter made short work of the old mounts and then we could start some welding.


We used a flat piece of stock to use as a cutting guide to give a nice clean line.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_110949806.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_110949806.jpg.html)


Here are both mounts trimmed up.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/23f66c3a-2730-443b-a3f2-6fb339188beb.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/23f66c3a-2730-443b-a3f2-6fb339188beb.jpg.html)


Here is the new front leaf hanger burned in on the frame.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_125256278.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_125256278.jpg.html)



After welding on the front mounts we cut the rear part of the frame off. Between the lines is 19 inches.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/fa702716-3a69-4216-b950-dc7971ef04d3.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/fa702716-3a69-4216-b950-dc7971ef04d3.jpg.html)


I'll end up plating off the frame with a piece of rectangle tubing that will also serve as a rear bumper and a place for some solid recovery points.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_131828378.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_131828378.jpg.html)


In the passenger frame rail there was a birds nest complete with eggs.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_131719763_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_131719763_HDR.jpg.html)



Here is the newly welded shackle hanger.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_133739977.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_133739977.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_214235226.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_214235226.jpg.html)



And a couple with the new axle rolled in to position. It isn't mounted yet. I still have to finish reassembling the leaf springs and I have to weld the spring perches to the rear axle.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_214210883.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_214210883.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_214221732_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_214221732_HDR.jpg.html)


The 37's and the Big axle absolutely dwarf the cab.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151017_214245499.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151017_214245499.jpg.html)


Anyway I'm pleased with the progress we got done. And and I'm grateful for good friends that came to help.

I should be able to get the rest of the rear done in the next week or so then I'll post up more progress.

Thanks again for reading and commenting and let me know what you think.

Zach.

ZachXJ1993
11-05-2015, 12:27 AM
The Brown Santa brought me some awesome goodies from Ruff Stuff!!!!
I have made several orders from the folks over at Ruff Stuff Specialties and I am never disappointed. The quality of their product is top tier and I'm not sure I would buy builder and fab parts from anyone else.
I ordered all the brackets and mounts to complete the front axle swap. What I received was enough 1/4 and 3/8 steel to choke a goat plus some very nice heim joints.

I'll work up a sketch of the suspension setup I plan to run.
I'll be using 2" by 1/4" Wall square tube for the lower and upper links. For the track bar I plan to run a piece of 1.5" by 1/4" wall DOM tube.
The lower links will mount to the existing lower radius arm mounts on one end, and will mount to a 2"X6" 1/4" wall crossmember/trans mount on the other. As for the upper link, I have a link tower to add to the passenger axle tube and a upper mount to zeus to the top of the crossmember and frame rail on the passenger side.
Should be super beefy!! I can't wait to get the suspension done!!
I guess I'm following the mantra of Over Axle/Suspension, Under Engine. I doubt that I'll have to many issues with breakage with this heavy of built suspension and axles. Only time will tell.


Here is the Massive 1.25" Heim joint with 5/8" misalignment spacers and weld in fittings for the 2" square tube.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151104_214550621_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151104_214550621_HDR.jpg.html)

Thanks again for reading and commenting.
Zach

4.3LXJ
11-05-2015, 10:58 AM
Pure beef there Zach

XJ Wheeler
11-06-2015, 07:28 PM
Just push x2 on the order button and i'll send you my address. :D

Gonna be sweeeet!

Sent via messenger pigeon - i talk, he types.

ZachXJ1993
11-25-2015, 12:46 AM
Hahaha!! I found this for sale in on the side of the road in Idaho Falls. The foot wells were full of water....Now they are full of ice! hahaha.
The sign says $2500 obo. It might be worth that if the engine had super low miles and was in perfect condition. Besides it has a ARB front bumper.


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20151124_144714274_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20151124_144714274_HDR.jpg.html)

TallGuyJeep
11-25-2015, 01:10 PM
Guess they really wanted a convertible...

ZachXJ1993
12-01-2015, 11:25 PM
Brown Santa visited today and brought me goodies from Novak Engine Adapters......

ZachXJ1993
01-16-2016, 02:27 AM
The time has come!! I have gathered more parts and have done more things on the Manch.

In my last post I alluded to the fact that I have my Novak engine mounts.

Here is what they look like.
They are super beefy and should be more than adequate for what I need them for. They have a real nice black finish on them. They also came with a super nice set of engine swap directions.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160115_234844836.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160115_234844836.jpg.html)



I have determined that next to a good welder the plasma cutter is pretty much the sweetest shop tool. I attempted to remove the old spring pads on the rear axle with a speedy-cut wheel on a angle grinder, and it was taking far too long.
So I broke out the Plasma and burned them off in about 10 minutes. I love that thing so much because it makes difficult projects a cake walk.

Here is one of the perches. All I had to do was blast out the welds and then hit em with a BFH and they broke off pretty clean. Then I ran over the remnants with a flap sand disk. The plasma cut into the tube just a bit. Probably around 1/16 or less. Not enough to hurt anything and I'll weld them up when I burn on the new perches.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160113_193918781.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160113_193918781.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160113_193924916.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160113_193924916.jpg.html)



I ordered some new rear leafs that are made to fit a 2004 Ford Ranger. I decided on them because they could be found for cheap and their dimensions were the closest to stock Comanche springs as I could find.
In fact really the only difference between them was the Ranger springs is the Ranger ones have 4 inches less free-arch, which is ok with me because I don't want 12" lift over stock.
I ordered them off Amazon and the were 100 each Prime shipped. I freaking love Amazon Prime.

Here they are with the axle rolled under them.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160113_195908667.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160113_195908667.jpg.html)



And Here is one of them bolted on.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160115_234943272.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160115_234943272.jpg.html)


I still have some things to button up on the rear but here is the top plate.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160115_234956324.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160115_234956324.jpg.html)



Once the rear suspension was somewhat put together I turned my attention to the engine bay. I have a complete standalone wiring harness that will fit my TBI 5.7 so I opted for the wiring genocide under the hood.

Before

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160114_152055119.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160114_152055119.jpg.html)


After

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160114_164025395.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160114_164025395.jpg.html)


Here are some shots of the removal.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160114_152751588.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160114_152751588.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160114_152838055.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160114_152838055.jpg.html)



Here is the mess we took out.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160114_164032791.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160114_164032791.jpg.html)



Now before you yell at me, let me explain. I know that I took out more than what I needed to for the engine swap. In fact I have gutted nearly the whole engine and chassis harness.
I am going to be redoing most of the chassis harness to eliminate all of the things that I don't need wiring for.
Such things I don't need are wiring for transmission module, ecm, that one yellow box thing, the maintenance timer, and anything that had to do with the old Chrysler/AMC diagnostics, and gauge cluster.
It might seem unnecessary to do this, but I want a super tidy and clean chassis harness that has just the essentials, without any of the unused stuff.
One of the other reasons is that my under-dash harness has some gremlins and many of the buttons switches and knobs don't work currently. I also don't have provisions for power windows, power locks, or power/heated mirrors. Those late model Cherokee doors have all the goodies and I'm gonna make all that stuff work because I can.


I decided to not mess around with making the GMC engine harness work in the Manch and I know that there are some bits of it that are no good (eaten by mice) and would need replacing. Also the wire loom is totally shot.
So enter my brand new harness from Fuel Injection Connection. This thing is sweet!!!
It came with some good details on how to hook it up as well as a wiring diagram.
The harness is completely standalone meaning that it needs keyed ignition power, battery, and the fuel pump hooked up. That's it. I'll run piggyback sensors for a set of aftermarket gauges.

Did I mention that this thing is sweet?! He uses GXP insulated automotive wire and new factory GM connectors to wire it. Also comes loomed and ready to go on the engine. It comes with a new fuse block and a fuel pump relay. everything is well marked and labeled and the build quality is superb.
One of the other reasons that I decided to purchase a harness versus building one is because I have a friend who fought with reworking one for his 350 YJ swap. Seemed way easier to do it this way, and for half the money of a Painless harness I couldn't pass it up.


Here are some pictures.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160116_245738811_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160116_245738811_HDR.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160116_245841635.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160116_245841635.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160116_245917488.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160116_245917488.jpg.html)



I'm way past the point of no return on the Manch so stay tuned for more updates as I get closer to engine swaps and front 3 link.

Thanks again for reading and Following the Build.
Zach

4.3LXJ
01-16-2016, 10:22 AM
I used a Painless harness in my conversion too. It made it all much simpler

ZachXJ1993
01-16-2016, 10:29 PM
Bit more done on the Manch today.

I ended up pulling the dash apart to remove the dash wiring harness and the fuse block.


Step 1. Remove the dash and other bits that attach to it.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160116_192934564.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160116_192934564.jpg.html)



Step 2. Remove the main wire loom that runs through every nook and cranny of the dashboard.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160116_192840536.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160116_192840536.jpg.html)



Step 3. Take said wiring and put it in the "I might still need this" box and then call it a day.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160116_192816375.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160116_192816375.jpg.html)



Thanks for commenting, following, and reading.
Zach

cantab27
01-16-2016, 10:57 PM
nice work mate ................

bluedragon436
01-17-2016, 01:02 AM
Looking good... I would definitely use a painless harness if I was doing a conversion.... Might as well do 97+ Interior swap since you got it all pulled apart already!! LOL... Look forward to seeing how the Manche progresses

ZachXJ1993
01-17-2016, 01:36 AM
Looking good... I would definitely use a painless harness if I was doing a conversion.... Might as well do 97+ Interior swap since you got it all pulled apart already!! LOL... Look forward to seeing how the Manche progresses

Yeah I have thought about doing a dash swap from a newer XJ but If I go away from the stock one I'll probably just do an tube dash like Dean Murray's.

Thanks for the input though.
Zach

4.3LXJ
01-17-2016, 10:48 AM
Just a suggestion on the dash. If you go 97+ you won't have a speedo and such. That is all drive by wire and you are getting rid of your ECM. You need to stick with the analogue gauges which you will still have to wire in since you removed that stuff too

Pookapotamus
01-17-2016, 11:51 AM
You know that feeling you get when you read a post, then just can't wait to head out to the shop and tear into your own projects???

That's what this post does to me! Keep up the great work and the awesome work with pics and descriptions! keeps us old farts working on our own rigs!

As for designing a new dash, I have been playing with that idea as of late my self, want to order some custom gauges, but the old dash has no room and not the greatest layout. I am also in the process of designing complete new wiring for Mort, if I am going to add a mega squirt to run the stroker might as well redo everything!

http://i264.photobucket.com/albums/ii191/pookapotamus/wiring_zpsvnuafdlo.png (http://s264.photobucket.com/user/pookapotamus/media/wiring_zpsvnuafdlo.png.html)

I am no where near finished but feel free to snag the pic and use what you can, in the end I will have all wires properly sized for amp and voltage load. And of course this is with all the little extras i plan on adding, like heated seats, and entry lights.

Keep up the great work Zach!!!!

ZachXJ1993
01-17-2016, 01:12 PM
Hey thanks for the suggestions and hints guys. I enjoy hearing feedback from you.

Steve, I plan to run a set of autometers or similar in the stock gauge cluster. I will probably just take apart the old gauge cluster and gut all the stuff inside and put in the new gauges for a stockish appearance.

Pookapotamus, I'm glad that i could help, and thanks for the wiring diagram. I'm and commercial and industrial electrician by trade, which just means I have an idea of how far in above my head I am. That diagram should be a good start though. My engine harness is already taken care of and I'll just have the chassis harness for engine monitoring and for the accessories, like heated Honda seats and power mirrors and all the offroad lights.

More progress soon
Thanks again guys
Zach

Pookapotamus
01-17-2016, 01:38 PM
Its not complete, but I am working on it, and its all on one page, little easier to understand than several connecting pages, and there are lots of upgrades and addons that I feel should have been included in a stock XJ. I will start posting updated ones in my build thread.

P.S. That pic is already out of date!

Carves
01-17-2016, 06:17 PM
Step 3. Take said wiring and put it in the "I might still need this" box and then call it a day.


Put the box at the back of a shelf ... Ive got 3 milkcrates that look like that,


... and its been many, many, many, days since I had the urge to poke around in them .. :D


... and I'll just post these pics of an aussie blokes, dash upgrade ... for your consideration.


http://i590.photobucket.com/albums/ss344/klemklubfoot/Mobile%20Uploads/20151212_142900.jpg

http://i590.photobucket.com/albums/ss344/klemklubfoot/Mobile%20Uploads/IMG_20151212_175759.jpg

ZachXJ1993
01-17-2016, 06:32 PM
I'm not a huge fan of wood grain, but I like the layout of those gauges.

Thanks for the idea.
Zach

ZachXJ1993
02-10-2016, 03:21 AM
Well I've got some pictures to share with everyone.
I have made some big changes to my game plan on the Manch.
A buddy of mine recently acquired a 93 YJ as a parts Jeep For his 1 ton build. It has a good drivetrain in it and he is now parting just about everything out.
The YJ has 140k on the clock and was in pretty good condition.
I am still going to be running the Chevy 5.7 out of the 1990 pickup, but I've opted to stay away from the 260k mile 700r4 that is in that truck. The YJ has a 4.0L H.O. and an AX15 trans, as well as a NP231J with a SYE installed. I'm going to run the AX15 with my V8 because why not. The trans was a steal at $200, and I think that a 5 speed behind that 350 will be a kick in the pants.
I did some checking because I was planning to run the 231J that was mounted behind the AW4 in the Manch, but the t-case inputs are different. The AW4 uses a 21 spline output and the AX15 has a 23 spline. It's not the end of the world because I can swap input gears in the transfercase and add a SYE kit. However the cheapest I've been able to find a 23 spline input for is about 70 bucks off Fleebay. And then you need different bearings which are another 40 or so bucks. Then add 200 for a SYE kit and I'd have paid for the t-case that my buddy is selling.
Another Interesting thing to note is that the NP241C that my GMC donor truck has is basically a beefed up 231J. the 241 has a wider chain and a 27 spline input. But the part I care most about is the 241C has a 6 gear planetary and the 231J only has a 3 gear planetary. I'm about 90% sure that they are interchangeable. And if they are I'll be running the 241C planetary in my 231J. I'll let yall know if that is something that can be swapped in or not.


After I got to looking at doing the AX15 conversion I was worried that the cost would far out weigh the benefits of the manual over the tired 700r4, but I was able to source some stuff for cheap.

I looked at two both of the two companies that I knew of that made adapters to do what I wanted, which were Novak Adapt and Advance Adapter.
The AA kit was is just under $500 and uses a 1-off adapter bellhousing. Then you are required to run their proprietary starter motor and mount for an additional $250. The clutch slave that the kit uses is off of a Toyota Land Cruiser and is not included in the kit. I think also you can only run a 10.5" clutch and 153 tooth flywheel with their kit. Which is why you have to run their special starter. To me it just seemed like a few too many 1-off parts that are expensive and are not available locally.

I looked up on Novak's site and saw that they had a adapter that was used to attach a GM bellhousing to the AX15. I called up Novak and started asking tons of questions about anything I could think of. They were very knowledgeable and helpful and made sure I understood what was required to make the swap happen. Their kit uses a standard GM bellhousing and a standard gm clutch and flywheel that was designed to fit the Chevy small block. As far as the slave cylinder goes they sell a kit but it was backordered. Overall the Novak kit seemed like a better choice because of availability of replacement parts and I can use stuff I already have.

I'm going to try and adapt the jeep external slave to work with the GM bellhousing. I'm not sure it will have enough travel to move the clutch fork but I'll give it a go. I'll prolly use the pedal out of that YJ as well.
After I figured I wanted to commit to the AX15 conversion I started calling around looking for a GM standard bellhousing.

I was able to find one at a local yard for 35 bucks!! It came out of a 1975 1-ton Chevy and came with the pivot ball and a fork as well. Even came with a custom grease/clutch dust coating.


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160205_194445921.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160205_194445921.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160205_194506512.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160205_194506512.jpg.html)



I got it all cleaned up and ready for new paint. One big reason I wanted to clean it was to inspect it for cracks because there were decent size bits of an exploded clutch stuck in the grease. It's pretty awesome how something made 40+ years ago will clean up and look good as new. I think it shows the quality of the materials and methods used to make the parts. And no cracks!


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_235004932_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_235004932_HDR.jpg.html)



Here is a picture of the drivetrain we janked out of that YJ.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160206_134604349.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160206_134604349.jpg.html)



This is the AX15 sans T-case back at my shop.


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160208_225214461.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160208_225214461.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_223245530.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_223245530.jpg.html)



Rear 23 spline output

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_223328297.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_223328297.jpg.html)



Clutch slave removed.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_224124598_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_224124598_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_224324257.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_224324257.jpg.html)



I then proceeded to remove the Jeep bellhousing.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_224336283.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_224336283.jpg.html)



There are nine bolts that hold the bellhousing to the transmission.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_225655518_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_225655518_HDR.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_230011470_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_230011470_HDR.jpg.html)



This is The Novak Adapt kit:

The main adapter plate which replaces the front input bearing retainer plate and includes a new shaft seal.

Bellhousing side:
http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_234729087_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_234729087_HDR.jpg.html)



Trans Side:

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_234716815_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_234716815_HDR.jpg.html)



This ring is machined to size the centerhole in the bellhousing from 5 1\18" down to 4 11\16". I believe this is required on all bellhousings newer than 1965. It makes sure that the bellhousing and the adapter/transmission are concentric.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_234647864_HDR.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_234647864_HDR.jpg.html)



This is the GM throwout bearing sleeve that is made to bolt to the adapter plate instead of being one piece like on the standard AX15 front bearing retainer.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_234834733.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_234834733.jpg.html)




You have to specify which pilot bushing that you need based on what year of AX15 you have and whether you are using a gen 1 or 2 small block or a LS based GM engine.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_234809862.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_234809862.jpg.html)



Novak supplies you a bag-O hardware to mount everything up.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/IMG_20160209_234815576.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/IMG_20160209_234815576.jpg.html)


Overall I am very happy with the quality of the Novak Kit and I'm excited to get all the bits and bobs attached and put together.
Looks like I better get that V8 pulled...

Let me know what you guys think. I'm really interested in your input and if you have any experience please share!

Thanks,
Zach

4.3LXJ
02-10-2016, 11:16 AM
Ha ha, you are working your way back. By the way, you can change that tcase input without a new bearing. Done that one. Keep up the good work

XJ Wheeler
02-16-2016, 09:40 PM
Looks great. I'm learning with every post so keep it up! [emoji106]

Sent via messenger pigeon. I talk, he types.

ZachXJ1993
03-26-2016, 11:37 PM
Wait What? A new post in the Manch thread?
So it's been quite a while since iv'e posted up here. But I have some pretty good progress to share. I have a larger pile of parts than I did a couple months ago. Now it's time to do something about it. Today was a pretty productive day. The drivetrain has been Janked out of the GMC and I seperated the trans and 5.7. I had some good help getting the engine out today, but I have been working on prepping for the pull for a week or so.

I started by getting all the junk out of the way. Core support, radiator, evap coil, wiring, hoses, basically everything that wasn't attached to the engine or trans.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160319_185358.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160319_185358.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160319_185413.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160319_185413.jpg.html)


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160324_182346.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160324_182346.jpg.html)


This was from this morning. A load leveler is a must we found out today. We pulled two complete drivetrains today and it makes a huge difference when trying to wiggle the whole thing out under the cab.


http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160326_102019.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160326_102019.jpg.html)


Apparently you can seal anything with enough duct tape...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/5b281f2e-b9e6-4a67-9950-3836f372c07d.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/5b281f2e-b9e6-4a67-9950-3836f372c07d.jpg.html)


And then I got them fellers seperated and then got the engine hung on a stand for a little TLC.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160326_183329.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160326_183329.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160326_183342.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160326_183342.jpg.html)


More progress coming soon.
I plan to take the the engine down to the short block and then change the headgaskets and the valve guide seals. It smoked pretty bad when I was driving it around last year. I also picked up complete top end gasket set, timing cover gasket, front crank seal, rear main set, oil pan gasket, valve cover gaskets, new water pump, cap, rotor, plugs, wires, and alternator. As well as a new clutch, flywheel, and pressure plate. Should be pretty sweet when I get it all back together and painted up orange.

Thanks for reading and commenting.
Zach

ZachXJ1993
05-22-2016, 02:50 AM
Time for another update on the Manch. I've got some good things started.
I'll let the pictures explain for the most part. My intentions with the donor 350 were to take it down to the short block and do gaskets, seals, and a coat of paint. hahaha Right!!!!

Got the engine hung on a stand.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160329_235853.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160329_235853.jpg.html)



I wasn't surprised to find lots of baked oil crust and residue after popping off one of the valve covers.
So I decided to continue the search deeper into the beast. I took the EFI bits off the intake manifold next and found the entire inside of the intake coated with dried and crusty oil. No good. Probably sucked excessive oil through a bad PCV valve. Oh and It's got 260k miles on the clock, which might have something to do with it.
Anywho onto the guts.

This is the moment I knew the ship was sunk. Under the intake was nasty. there was oil cake everywhere and oil buildup on all the surfaces.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/16bb4765-53e4-4fbb-a0f7-5c6eddcad4ef.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/16bb4765-53e4-4fbb-a0f7-5c6eddcad4ef.jpg.html)



After finding that mess in the lifter valley I figured it couldn't get much worse and figured that a rebuild was going to be in the near future.

The next song was to get the rockers loose and pull the heads. I pulled the passenger head first. Under there were black pistons and worn cylinder walls.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_005052.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_005052.jpg.html)



This is a shot of cylinder #4. It was in the worst shape of the 4 on this side.
What appeared to be a thick carbon ring around the top of the cylinder was actually a wear ring in the bore. #4 was wore about .012" over all the way around. That ring made it a pain to remove the pistons.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_005119.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_005119.jpg.html)



This is the underside of the passenger head.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_005207.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_005207.jpg.html)



The intake ports were pretty sad as well. And the water ports were full of crud. Along where the intake mates up to the head there was evidence of gasket failure.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_005246.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_005246.jpg.html)



This is after removing all the pistons and rods. The crank seemed to be in pretty good shape. Even wear across all the rod journals and mains.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_202950.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_202950.jpg.html)



Here is the timing set, which like everything in this engine was worn out.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_190310.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_190310.jpg.html)



I pulled the cam and found plenty of wear on all the lobes. I'd imagine the cam was pretty flat.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160330_202925.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160330_202925.jpg.html)



All in all I had three choices. Buy another used engine and take a gamble, buy a rebuilt or crate long block, or have mine gone through by a machine shop.
I decide to go get a second opinion and took the long block down and had it all looked at. They confirmed what I figured and recommended some machine work based on the tolerances they found throughout the engine. They gave me a very reasonable quote to do the work. So I decided to do a full rebuild on the engine I already had.
One other reason that I chose to rebuild instead of buy new is I like to support local business.

So then the waiting began. hahaha every time my phone rang I was hoping it was the shop calling to let me know it was ready. I felt like a ten year old during the week before Christmas. Is it here yet? Is it time? Anywho I'm glad I went the way I did.


When I went to go pick it up I was amazed at the transformation.

The block, heads, and rods were tanked and cleaned as well as inspected for cracks.

The cylinders were bored .030" over to clean up the walls and to allow for a good hone.
The block was squared up in relation to the crankshaft by machining the decks flat.
New camshaft bearings were installed as well as new oil and freeze plugs.
To top it off it was painted black.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160504_211550.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160504_211550.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160504_211857.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160504_211857.jpg.html)



On the heads the seats had some bad pitting, and the guides were wore.
New guides, and seats were installed and lapped to the Valves.
The heads were machined to get them nice and flat as well.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160511_185701.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160511_185701.jpg.html)


The main caps were in good shape so no need for line honing. New standard size bearings were used on the mains.
The crankshaft was within spec so the main and rod journals were polished.
Here it is ready for install

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160504_225718.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160504_225718.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160504_232646.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160504_232646.jpg.html)



Crankshaft installed and torqued to spec.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160504_233357.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160504_233357.jpg.html)



The factory rods were inspected and installed onto new pistons.
New piston rings used as well.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160507_183540.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160507_183540.jpg.html)



Here is the bottom end with all the rods torqued to spec.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160509_185501.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160509_185501.jpg.html)



The camshaft is new. It is a sealed power flat tappet cam with a mild torque profile. It was less expensive than the speced OE cam. And I'll have a bit more torque to boot.
If you are interested I can post a picture of the Cam-sheet that lists the specs and the part number.
The truck engine came factory with a flat tappet cam rather than a roller cam. The block has provisions for a roller cam but the price to upgrade was a bit more than what I wanted to spend.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160504_223225.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160504_223225.jpg.html)



New timing set.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160509_191635.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160509_191635.jpg.html)



New lifters.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160511_182651.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160511_182651.jpg.html)



Heads installed and torqued to spec.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160511_200233.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160511_200233.jpg.html)



New pushrods and rocker arms.
Valves lashed and pre-load set.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160511_215923.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160511_215923.jpg.html)



The stock TBI intake was pretty awful. It had some buildup in it that wouldn't come out. So instead of risking my rebuild not running right because of that intake I decided to replace it.
This is a Eldebrock Performer TBI intake. Basically it is the factory Gm part but it has a few things done to increase performance.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160512_205320.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160512_205320.jpg.html)



I installed a new oil pump as well as new pickup screen. I did some research and Meling recommended it be set 3/8 above the pan bottom and welded to keep it from moving.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160517_223558_1.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160517_223558_1.jpg.html)



The timing cover, oil pan braces, fuel pump block off plate got painted Chevrolet orange.
I decided to replace the oil pan and the valve covers because the insides of them were more than I wanted to clean. The oil pan a a sizable crease in it as well.
I was able to find some replacements for pretty inexpensive.
I am going to run a remote oil filter, with temperature bypass for a oil cooler. So you can see the adapter installed in the block. It has two 1/2 NPT holes and I'm using some AN-10 fittings and braided hose to complete the filter circuit.

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160519_195929.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160519_195929.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160519_195941_1.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160519_195941_1.jpg.html)



The valve covers I bought came chrome, but I don't believe in chrome. There will be other parts on this Jeep that will "get me home". So I painted them to match the theme.

Before...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160521_194006.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160521_194006.jpg.html)



After...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160521_214600.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160521_214600.jpg.html)



There are other things that I have done like clean up the accessory brackets and paint the pulleys. I put all the parts in the blast cabinet and went to town. I also replaced the bearing on the belt tensioner.

before...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160406_222739.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160406_222739.jpg.html)



after...

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160406_221535.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160406_221535.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160406_220222.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160406_220222.jpg.html)

http://i849.photobucket.com/albums/ab52/Lil_Z_99/The%20Manch/20160406_221519.jpg (http://s849.photobucket.com/user/Lil_Z_99/media/The%20Manch/20160406_221519.jpg.html)



Overall It has been way fun and a good experience to build an engine. I can't wait for first start. I feel pretty accomplished with the work I've put into cleaning and assembly.

There is plenty more to do still, but I'm making progress.

Let me know if you have any questions. And comments and pointers are always welcome.
Thanks again for reading and commenting.
Zach

4.3LXJ
05-22-2016, 08:32 AM
Nothing like clean, tight and shiny. Nice job

Mudderoy
05-22-2016, 11:21 AM
I haven't done it many times, and I'm always nervous on that first start up, but engine building is fun.

Pookapotamus
05-22-2016, 01:30 PM
Looks great! Like the colour scheme!


Having 4WD means getting stuck in more inaccessible places!