My 5.0 coilover build

navman · 12-22-2009, 06:00 PM

This started out as a simple frame swap to replace a badly rotted frame that quickly led to another jeep addiction.
Initially went from a stock 4 cyl stocker to an RE XD4.5 sua with a set of procomp 35" XMT's. I picked up a clean frame, and started gathering parts for a V8 swap while I wheeled the old frame.

navman · 12-22-2009, 06:20 PM

My initial design was to stretch the rear 3" and swap in a ford 8.8, along with a genright ext tank. I didn't want to go comp cut and more stretch cause I still like to bomb around town and that would be a bit much to get away with. I also wanted to do something to improve the front, especially the low shackle height. I debated about what coilover setup to do and after talking to several companies decided on the RockKrawler X factor plus comp 7 kit. I was able to get the front kit only, including the center skid plate/mount and still utilize my streched rear leaf setup. This would stretch the front 2" and give me about a 99"wb. I also picked up a hydraulic bellhousing and np435 tranny from an 85 f250 and an 89 mustang 5.0 v8. I went to Novak for a lot of parts including a rebuild kit for the np435.

navman · 12-22-2009, 06:30 PM

I also used an np435 to np231 adapter kit from Novak and got a new np231hd transfer case from JB conversions. I added a Novak tcase shifter linkage kit to the mix. After dealing with not enough throw from the ford clutch slave, I added a Novak 3/4" slave that took care of the problem completely. The stock skid shown in the pic was not used in the build.

justanotherjpr · 12-22-2009, 06:32 PM

Shaping up to be a good one!

navman · 12-22-2009, 06:36 PM

Next was a mustang kevlar clutch from zoom. While this was a good choice for performance, the smaller flywheel required some rethinking for a starter. I went to a powermaster with the infilock mount, then redesigned the mount to move the starter in closer to the new flywheel. I can't say enough about the starter durability. I ran a whole day with no clutch due to a cheap plastic master failure, and had to start in gear in all sorts of situations, and it never failed.

navman · 12-22-2009, 06:46 PM

After all the mockup and days of cutting off stock mounts, it was time to start welding. 2 full days later that was finished. My friend Kenny deserves all the credit for the welds, no way I could match that let alone trust it. Parts included in this are, RockKrawler center skid/mount section, coilover mounts, frt tracbar mount, Novak motor mounts, MORE rear frame plate, Poison Spider rear corner reinforcements, BTF rear main eye spring mounts, Genright rear shackle hangers.

navman · 12-22-2009, 06:48 PM

and some more

navman · 12-22-2009, 06:52 PM

After a coat of por 15, it was time to start assembly.

navman · 12-22-2009, 06:58 PM

Here's some poser flex shots I took while figuring out driveshaft lengths. I went with Tatton shafts for both the cv rear and standard front. Great prices and next day shipping. Several guys I wheel with are using his driveshafts and they stand up real well. I maxed out the cpicker before I maxed out the suspension. Gave me enough info for the measurements though.

navman · 12-22-2009, 07:04 PM

The next pics show the Novak radiator as well as the flexilite fan. I have about an inch between the motor and firewall and 3/4 of an inch at the fan. Countless hours of mockup paid off as no adjustments were needed at final assembly.

wrangler76 · 12-22-2009, 07:13 PM

Good to see the oval instead of a bowtie!!! Been toying the idea of doing a similar swap but with a spare 4.0 sitting on an engine stand in the shop I'm not sure I can justify it....

navman · 12-22-2009, 07:16 PM

Next is the front axle, steering and brake setup. For right now I'm still running a d30 with an ARB and alloy usa shafts. I have a Bulletproof otk steering setup with hiems. I went to a single rubber line down to the axle for the brakes, then went out to the sides from there with hard line and to stainless for the outers to the calipers. I eliminated the factory ditribution block after the master and just put a proportioning valve on the rear line. Got this whole idea from John, a fellow jeep club member. An ARB cover finishes it off. A Riddler cover for the 8.8 and Currie ubolt skids/shock mounts for the rear.

navman · 12-22-2009, 07:20 PM

Thanks justnotherjpr and wrangler76. By the way wrangler76 the 5.0 is about 70 lbs lighter than the 4.0, not to mention the v8 sound.

navman · 12-22-2009, 07:24 PM

This is how it sat after the initial build. It was a little low in the rear and the 35's just didn't quite cut it.

navman · 12-22-2009, 07:38 PM

I changed the RE XD4.5 rear springs for a set of BDS 5" springs to level it off. They work rear well and added the little extra height I wanted. I also got a set of Pitbull 37" rockers on Procomp 10" wheels to get the tire size and extra width I wanted. Next on the list will be a new front axle, but I haven't decided on what to get yet. The power is great and the suspension performs real well too. I know it doesn't have the lcg look everyones looking to do right now, but I tried to keep the weight low and/or centered with things like the ext tank vs doing a fuel cell up in the rear cargo, as well as the motor/tranny position. So far I'm real happy with it and it works good for the terrain I wheel.