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Unread 12-06-2012, 10:15 PM   #1
Mr.ThunderMakeR
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1991 YJ Wrangler 
 
Join Date: May 2007
Location: , AZ
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Trans Swap Alignment Problem

My new trans is in but the mount holes aren't lining up in the skid plate. I expected to have to elongate the holes, but its actually off by an inch to the side. Should I just drill new holes where its lining up? I'm afraid if I do the new holes will merge with the existing slots and be too weak.

It looks like it is close enough to maybe shift it into place. Should there be enough play in the motor mounts to shift the whole drive train an inch to the side? I tried this but it wasn't seeming to budge.

Also the rear output flange looks like its off by about an inch sideways with respect to the rear axle pinion. Is this a problem? Does the rear output of the transfer case need to be aligned side-to-side with the pinion? Sorry I don't have a pic of this atm.

Mount:


Not lining up:



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Unread 12-07-2012, 07:04 AM   #2
notmyj
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What do your.motor mounts look like? If they are worn it could cause this. My rule is if the motor mounts are good, shift it side to side and enlongate the holes as needed when doing a granny swap. I had to do this when I swapped in the AW4. If all things are stock, then shift it around till it fits.
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If it has tracks, tires or tits, its gonna cause a problem.

"Everytime someone "upgrades" a D35, an angel looses its wings."

"Dizzy" - What SnoopDog would call a Distributor if he was a mechanic. I cringe every time I hear this moronic term

Quote:
Originally Posted by Warren Zevon
Send lawyers, guns and money. The **** has hit the fan...
92, 4.0, AW4, 8.8, D30, 15x10, 37's, SOA etc, etc
92, 2.5, 30, 8.8, 4.88, Locked, Winch, 15x8, 35's, 3.5" (RIP)
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Unread 12-07-2012, 09:17 AM   #3
Mr.ThunderMakeR
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The passenger side looks good, I also replaced the cradle with a brown dog cradle (yellow piece)



I'm not sure about the driver side though:

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Unread 12-07-2012, 09:27 AM   #4
notmyj
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driver side mount is toast. This.will cause.your problem... might as well get new mounts so your tranny mount lasts.
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If it has tracks, tires or tits, its gonna cause a problem.

"Everytime someone "upgrades" a D35, an angel looses its wings."

"Dizzy" - What SnoopDog would call a Distributor if he was a mechanic. I cringe every time I hear this moronic term

Quote:
Originally Posted by Warren Zevon
Send lawyers, guns and money. The **** has hit the fan...
92, 4.0, AW4, 8.8, D30, 15x10, 37's, SOA etc, etc
92, 2.5, 30, 8.8, 4.88, Locked, Winch, 15x8, 35's, 3.5" (RIP)
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Unread 12-07-2012, 09:49 AM   #5
Brown Dog
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I can't see the mount well enough to be sure, but unless the elastomer is cracked it looks pretty good to me. I talked to a customer recently who had the same problem you are experiencing. In his case he had a number of P.O. issues (hack-job repairs). In you case it appears to be a straight up AX-5 replacement. The motor mounts can handle a 1" shift; don't worry about that. Be looking around to see if anything has strayed and is wedged in somewhere that would cause the shift. I'm thinking of things that might be in the tunnel, or something like that. Are you able to freely move the rear of the transfer case from left to right?
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Unread 12-07-2012, 10:41 AM   #6
notmyj
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there is a large gap in the driver side mount between the rubber and the metal housing. Unless I am misinterpreting the pic, it would seem this gap in the mount would cause the movement.
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If it has tracks, tires or tits, its gonna cause a problem.

"Everytime someone "upgrades" a D35, an angel looses its wings."

"Dizzy" - What SnoopDog would call a Distributor if he was a mechanic. I cringe every time I hear this moronic term

Quote:
Originally Posted by Warren Zevon
Send lawyers, guns and money. The **** has hit the fan...
92, 4.0, AW4, 8.8, D30, 15x10, 37's, SOA etc, etc
92, 2.5, 30, 8.8, 4.88, Locked, Winch, 15x8, 35's, 3.5" (RIP)
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Unread 12-07-2012, 10:57 AM   #7
Brown Dog
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Quote:
Originally Posted by notmyj View Post
there is a large gap in the driver side mount between the rubber and the metal housing. Unless I am misinterpreting the pic, it would seem this gap in the mount would cause the movement.
That is actually normal with the OEM 2.5 mount...believe it or not.
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91YJ 2.5
Brown Dog Mounts and Engine Brackets (Serial Number 1)
2" BL
4.5" Superlift SL
AA SYE
35" GoodYear Mud Terrains
Conteract Balancing Beads
Bulldog front bumper
Best Top seats
"Family" roll bar
25 foot 1/2" log chain
No Top, No Doors (Best Top Safari)
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Unread 12-07-2012, 11:16 AM   #8
notmyj
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Just learned something new.
__________________
www.pghoffroad.com
My SOA Build
Recovery Gear Basics
My BUDGET York OBA Install
Budget Welding Cart
Carling Contura Switch Panel

If it has tracks, tires or tits, its gonna cause a problem.

"Everytime someone "upgrades" a D35, an angel looses its wings."

"Dizzy" - What SnoopDog would call a Distributor if he was a mechanic. I cringe every time I hear this moronic term

Quote:
Originally Posted by Warren Zevon
Send lawyers, guns and money. The **** has hit the fan...
92, 4.0, AW4, 8.8, D30, 15x10, 37's, SOA etc, etc
92, 2.5, 30, 8.8, 4.88, Locked, Winch, 15x8, 35's, 3.5" (RIP)
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Unread 12-07-2012, 11:18 AM   #9
Brown Dog
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Yeah, your 4.0 mounts aren't like that. On the 2.5 you really have to look for cracked rubber.
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91YJ 2.5
Brown Dog Mounts and Engine Brackets (Serial Number 1)
2" BL
4.5" Superlift SL
AA SYE
35" GoodYear Mud Terrains
Conteract Balancing Beads
Bulldog front bumper
Best Top seats
"Family" roll bar
25 foot 1/2" log chain
No Top, No Doors (Best Top Safari)
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Unread 12-07-2012, 01:58 PM   #10
Mr.ThunderMakeR
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Quote:
Originally Posted by Brown Dog View Post
In you case it appears to be a straight up AX-5 replacement. The motor mounts can handle a 1" shift; don't worry about that. Be looking around to see if anything has strayed and is wedged in somewhere that would cause the shift. I'm thinking of things that might be in the tunnel, or something like that. Are you able to freely move the rear of the transfer case from left to right?
Its actually a NV3550 swap, with Rubicon tcase. But I imagine the alignment should be the same. There is a little bit of wiggle side to side but not much. It feels like the motor mounts are preventing the movement. I'm gonna try loosening the motor mounts and anything else it might be bound up on and shift it into place.

Kinda like Mean Max's post in this thread:
http://www.jeepforum.com/forum/f12/m...stion-1013737/
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Unread 12-07-2012, 04:24 PM   #11
Mr.ThunderMakeR
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I tried to get a picture of the rear pinion alignment but its difficult to show clearly:



Do these need to be aligned?
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Unread 12-07-2012, 04:45 PM   #12
Brown Dog
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Yes they do.
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91YJ 2.5
Brown Dog Mounts and Engine Brackets (Serial Number 1)
2" BL
4.5" Superlift SL
AA SYE
35" GoodYear Mud Terrains
Conteract Balancing Beads
Bulldog front bumper
Best Top seats
"Family" roll bar
25 foot 1/2" log chain
No Top, No Doors (Best Top Safari)
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Unread 12-07-2012, 05:57 PM   #13
Mr.ThunderMakeR
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Ok thanks for the help. Ill try to get it straightened out
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Unread 06-13-2013, 03:54 PM   #14
Mr.ThunderMakeR
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Just thought I would update this for future readers...better late than never I guess. I got it lined up by using a ratchet strap around the frame and the tcase. Easy as pie.
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