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Unread 09-16-2006, 05:14 PM   #1
northjeep
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Build Thread - Peugeot BA10/5 to NV3550

Legal disclamer:
These are not instructions!
Always work safely and under supervision.
Do not attempt the following at all unless you are qualified!
I do not accept any responsibility for your actions based on this article.
By reading further you release me and this site from any responsibility and further indemnify me from any financial remuneration, legal proceedings or otherwise.


Vehicle Background:
What we have here is an 88 YJ (see specs). It has a 4.2 and fuel injection from SDS. The guy who sold it to me claimed figures of about 160hp and 180ft/lbs (at the wheels). Who knows, but it was strong enough that I DESTROYED reverse gear without too much effort and in short order (1st is complaining too). I had budgeted replacing the tranny from the moment I purchased my heap.

Rebuild Options/Goals:
I was entertaining many options including rebuilding the 10/5, going to an ax-15, and springing for the NV4500!
My goal with this swap is simple...Get back on the road with a NEW transmission (not rebuilt or yard sourced) that will handle most anything I dish out, and not open a huge can of worms. So I did a mess of research on the NV3550.

Turns out it fit the bill...here's how.

Rebuild Obsticals:
I faced some of the following problems.
  1. Budget
  2. Swap complexity
  3. Actual durability
  4. Future torque handling capacity
  5. Timeframe
Budget:
We all know the prices so I wont bore you with that. Lets just say I cant afford to do this twice.

Ease of swap:
The AX-15 would probably have been just as easy to swap as the 3550 and I'm sure many people are very happy with the 15. I might have gone AX-15 but the ratios/torque capacity is better in the 3550. The 4500 is huge and awesome...but there's a bunch more fab work and drive shaft stuff that needs doing for that swap.

Actual Durability:
Considering my torque requirements (current and future) I have decided that I will never ever go above 300 lb/ft from the engine. Given that I will be using this jeep as a daily driver and mild crawler/tow vehicle, I won't be needing a "trail rated" granny low, or huge torque capacity. The NV3550 is rated 300 lb/ft (conservatively) based on a GVW of 7200 lb.
I think my jeep is, at most, half that weight.

Future Torque Capacity:
If I am correct in assuming my injected 4.2 is producing about 207 ft/lbs at the crank (180x1.15), then it's safe to say I'm in the clear with the current motor. However, assuming the conservative rating of the 3550, if I do swap in a nice new 4.0 and stroke it with the old 4.2 internals, or go with a 3.8 S/C (who knows), I will still be safe.

Timeframe:
I want a "drop-in" tranny upgrade!! Unfortunately those don't come easy. The idea of fabricating for weeks and trouble shooting after that, puts most "granny low" transmissions out of the picture for me. Time is not a huge factor for me, but I don't want to be on my back in a frozen garage, battling with mechanical jigsaw puzzles. The best solution is coming into focus...

Let the sparks fly!
So I ordered the NV3550 conversion kit available from High-Impact Transmission & Gear

EDIT:
I never included a parts list with part numbers...so here it is complete with links.
For reference from another thread: '92-'99 AX15 and NVG3550: OEM pilot bearing 53009180AB for '87-'91 engine

Advance Adapters Bell housing kit incl release lever, throwout bearing and pilot bearing p/n 712590

(P/N 715545) NV3550 Shifter Bracket (for Jeep NP231 transfer cases)

23 spline transfer case input conversion

(P/N 716007) NV3550 Crossmember Mount Kit (for Jeep YJ Wranglers)

(P/N 716340) Jeep Slave Cylinder Kit For NV3550

Stage one - Teardown:

2 huge boxes arrived at my door after waiting patiently for my Sept. X-mas. The Tranny in one and the adapters/clutch in the other.

I took a quick inventory of all the stuff..."yup all there....woah....whats THAT?"....A chipped Clutch plate that's what.<Replaced Free of charge by Advance Adapters after some E-mailing and picture taking. (AA is a great company)


Parts...check.
Tools...check.

Started by removing the shifters.


Then the front and rear drive shafts came off.



The rear U-joints were in a bad state. One literally fell apart right away, displaying the roller bearings inside. The other was seized.

Next I lowered the belly pan.

This is about the point when I broke out the ziplocks for labeling and storage of "loose items".

Then I removed all the vac lines, speedo cable, backup light wires, vent tubes, and cobwebs and removed the x-fer case.






Next installment I'll give a step by step on replacing the input gear in the np231 (from 21 to 23 spline).

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Last edited by northjeep; 05-09-2010 at 11:36 AM.. Reason: Updates man updates
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Unread 09-16-2006, 05:33 PM   #2
mp3coupe
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couldn't do click free for ya, sorry
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Unread 09-16-2006, 05:41 PM   #3
northjeep
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Here's the hole left by the x-fer case.
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Last edited by northjeep; 07-24-2008 at 02:49 PM..
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Unread 09-17-2006, 04:32 PM   #4
MichInCT
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Hey NorthJeep, can ya give me the ttal expen$e when you're done ? I'm interested in doing the same.

Thanks.... MichInCT
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Unread 09-17-2006, 04:41 PM   #5
northjeep
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Quote:
Originally Posted by MichInCT
Hey NorthJeep, can ya give me the ttal expen$e when you're done ? I'm interested in doing the same.

Thanks.... MichInCT
Sure, I'll post a rundown at the end of my build.
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Unread 09-17-2006, 09:00 PM   #6
Richmond88yj
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If you finish it by next Sunday, you can win a free membership.

Great write up so far!!!!!!!
http://www.jeepforum.com/forum/f7/treasure-hunt-membership-contest-3-write-ups-316199/


Here's my thread on a BA=10/5 to AX-15, hopefully it helps you a little.
http://www.jeepforum.com/forum/showthread.php?t=312191
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Unread 09-17-2006, 11:26 PM   #7
northjeep
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Installment #2 - NP231 Input Gear Replacement

First I cracked open the case...


Then Removed the mode and range forks...


(note the main-shaft synchro snap ring in the photo below)


off comes the main shaft, chain and front output shaft.


That leaves the main shaft and back half of the case...


After removing the planitary retainer on the transmission side of the front half, the planitary and input gear comes out as a unit...then remove the input gear retainer...(note there is no need to remove the large ring gear retainer inside the case)


Then note the position of the input gear thrust washers...


Now you can clearly see the two input gears side by side (new left, old right)...


Installation is the reverse of removal.

Then removing some more retainers...


Off comes the pump housing...


Continued...
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Last edited by northjeep; 07-24-2008 at 02:51 PM.. Reason: Pictures man Pictures
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Unread 09-17-2006, 11:30 PM   #8
northjeep
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Here's an overview while everything is undone...


Next installment? Get ready for Trial fitting, pilot bushing installation, clutch alignment, bracket fitment and more.
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Last edited by northjeep; 07-24-2008 at 02:52 PM.. Reason: Pictures man Pictures
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Unread 09-21-2006, 02:45 PM   #9
roksamy
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Awesome

Great build thread , Northjeep , Wish I was there to help ya get that membership Call me if you need anything else
-Josh Cumby High Impact Transmission & Gear
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Unread 09-21-2006, 02:49 PM   #10
northjeep
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Thanks Josh!
Your kit makes this swap FuN & EasY.
Update coming tonight...
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Unread 09-21-2006, 08:03 PM   #11
northjeep
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Installment #3

Here's the Transfer Case test fit to the NV3550


Release arm and throwout bearing in place.


MMMMMMM Beefy.


Advance Adapters shift bracket with "Z" gate installed from old bracket.


Here's a good example of a flywheel in need of resurfacing. It's glazed and scored pretty bad.


I pulled the pilot bearing with a $25 puller. Worked great and fast.


Dead pressure plate. *note the bluing and scoring


The old clutch plate is at about half wear.


And Finally the old TURD from two angles.


More to come.
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Last edited by northjeep; 04-30-2010 at 10:10 PM..
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Unread 09-21-2006, 08:37 PM   #12
jeepin92yj
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is that tranny still good? because i might be needing a few parts or even a new tranny
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[SIZE="5"][B]-Black Betty-[/B][/SIZE]

[SIZE="1"]4.0L 5spd[/SIZE]
[SIZE="1"]Rubicon 4" kit (5" of total lift)[/SIZE]
[SIZE="1"]5/8 Boomerang Shackles[/SIZE]
[SIZE="1"]2" body lift[/SIZE]
[SIZE="1"]35x12.50r15 Mickey Thompson MTZs[/SIZE]
[SIZE="1"]Ford 8.8 Rear with Rugged Ridge diff. cover [/SIZE]
[SIZE="1"]4.88s[/SIZE]
[SIZE="1"]Detroit locker in rear and Lock Right up front[/SIZE]
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Unread 09-21-2006, 08:43 PM   #13
northjeep
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A complete rebuild would be required.

Reverse is broken...1st is complaining...and after looking at the input shaft I was supprised to find about 3/64" play at the pilot bering end.

However the PO replaced the throwout bearing and internal slave. So if you need that lemmy know.

EDIT: that tranny wasn't even good from the factory!!!
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Unread 09-21-2006, 08:48 PM   #14
jeepin92yj
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what about that slave and throwout brearing. i need a new bearing and it wouldnt hurt to replace the slave while im at it
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[SIZE="5"][B]-Black Betty-[/B][/SIZE]

[SIZE="1"]4.0L 5spd[/SIZE]
[SIZE="1"]Rubicon 4" kit (5" of total lift)[/SIZE]
[SIZE="1"]5/8 Boomerang Shackles[/SIZE]
[SIZE="1"]2" body lift[/SIZE]
[SIZE="1"]35x12.50r15 Mickey Thompson MTZs[/SIZE]
[SIZE="1"]Ford 8.8 Rear with Rugged Ridge diff. cover [/SIZE]
[SIZE="1"]4.88s[/SIZE]
[SIZE="1"]Detroit locker in rear and Lock Right up front[/SIZE]
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Unread 09-22-2006, 05:16 PM   #15
northjeep
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Got the clutch in the mail today.
Looks like I might get it done over the weekend!!!!
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Tags
87 88 89 yj wrangler , nv3550 , part numbers , peugeot ba10/5 , transmission swap

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