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Unread 12-03-2011, 09:44 PM   #1
youngjeeper11
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XJ HVAC system in YJ.....Lets try it..

In my endless quest to add creature comforts to my YJ, I have been debating what I want to do about HVAC. I really dont like the YJ HVAC system, and I want A/C, but I do not want to use one of those under dash AC units, also, I am designing a custom dash, and I really want to add heater vents.

So I researched a few universal hot rod type HVAC units, they are nice, but really pricey.

So what am I left with? A trip to the junkyard today shed some light on my situation. I walked around for a few hours checking out mostly cherokees that had the dashs already torn apart to see how their HVAC systems went together.

I finally decided I could probably take all the A/C components from an XJ, including the controls, vacuum lines, vents, and the entire heater/AC housing, including the blower motor, heater core ect, and retro fit it all into my YJ.

So I found an XJ with an untouched interior that was in good shape, and with the steering wheel already gone. Within an hour and a half, I tore everything I needed out (besides the compressor, condensor ect, mainly because I need to decide what I am going to do for a compressor on my 4BT anyway and the junkyard was closing)

Only cost me $60 bucks so far, tomorrow I am going to do some test fitting to see if I can even get it to work.

If I get it all to work, I will have a more reliable HVAC system without a bunch of cables, and AC hidden behind the dash.

What do ya'll think?

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Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

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Unread 12-03-2011, 09:52 PM   #2
moonshinefuel
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Unread 12-04-2011, 05:19 AM   #3
Dre40
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I had thought about doing an XJ dash in my YJ a while back but never got around to doing it.. would like to see how it works out for you...
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Unread 12-04-2011, 06:03 AM   #4
twiisted71
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Quote:
Originally Posted by youngjeeper11 View Post
I will have a more reliable HVAC system without a bunch of cables

Please don't be stingy with the info and lots of pics (whether it works or not). By the way I want to rig mine up with cables as I don't intend to run any vacuum components.
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Unread 12-04-2011, 07:23 AM   #5
Spuznick242
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Sounds sweet, I'm intrested...create a build thread and add it to all your others. The only thing is that when I do my 4bt swap I dont care about air coniditioning, I much rather have OBA.
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Unread 12-05-2011, 03:29 AM   #6
youngjeeper11
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I got around to doing some test fitting yesterday, and I think it is going to work out a lot better than I initially thought. I just need to cut a hole in the firewall for the ac hoses. I can't post pics from my phone so ill post them tonight
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Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

Ask me about my 4BT Cummins Motor Mounts!!
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Unread 12-05-2011, 05:17 AM   #7
youngjeeper11
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Quote:
Originally Posted by Dre40 View Post
I had thought about doing an XJ dash in my YJ a while back but never got around to doing it.. would like to see how it works out for you...
I thought about doing the whole dash as well, but the one thing I noticed that would be hard to get around is that where the dash meets the windsheild is rounded to the contour of the windsheild, and YJs are totally flat so I think it would be difficult to get it to look right.
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Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

Ask me about my 4BT Cummins Motor Mounts!!
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Unread 12-05-2011, 06:01 AM   #8
Dre40
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you would definitely have to re couture it and do some modifications.. but I think its possibly.. I even looked at an TJ dash as well..but tho are hard to come by.
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Unread 12-05-2011, 06:39 AM   #9
twiisted71
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Are the levers that control the various flaps/doors on the outside of the XJ box? I'm going to go with a CJ dash so hopefully that will make vent placement more aesthetic. This sure would be nice instead of having to run 2 separate air handlers, I hope its easy to figure out.
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Unread 12-05-2011, 10:17 AM   #10
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I could see using the air box from the xj could work to a point but getting the air from there to the vents would be another challenge it's self. sure you could use flexible hoses and such but then where are you going to mount them. You will have to remove the front speakers for vents and then that would not be that big of a deal. Your center vents would to be added. Where are you thinking about putting them?
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Unread 12-05-2011, 11:14 AM   #11
youngjeeper11
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Quote:
Originally Posted by dodger889 View Post
I could see using the air box from the xj could work to a point but getting the air from there to the vents would be another challenge it's self. sure you could use flexible hoses and such but then where are you going to mount them. You will have to remove the front speakers for vents and then that would not be that big of a deal. Your center vents would to be added. Where are you thinking about putting them?
I stole all the vents and ducting (minus 1 hose that I dropped trying to carry everything out including my tools with the person on the loud speaker at the junkyard yelling "cash register closes in 5 minutes")

I am designing a totally different dash all together

http://www.jeepforum.com/forum/f12/y...esign-1273153/

So I can put the vents where ever I want. I figured I would get this installed before finishing my dash design to make sure i get everything right.

I will post pics tonight, but I was surprised how similar the units are in shape and vent location, I will almost definitely be able to use the same hole in the firewall for the blower motor, and there is already an "indent" in the YJ firewall that nearly matched the hole needed for the AC and heater lines, almost like this unit was supposed to fit in a YJ. I have high hopes it is going to work, I also noticed the blower motor in the XJ unit is much larger that the one in the YJ unit.

All the vents except 1 are vacuum operated, but the levers and everything are external, you could probably work out a cable system, but I think its slick because the whole unit can be removed by just connectors, including wiring harness and vacuum lines, its practically plug and play. Some of the vents are slightly different sizes, but I am sure I can fab up some quick sheetmetal adapters.

all this talk, and no pics, I will post tonight!
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Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

Ask me about my 4BT Cummins Motor Mounts!!
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Unread 12-05-2011, 02:54 PM   #12
twiisted71
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LOL yea get in gear and post up some pics. Not that it matters to me as I'm out of commission with some dislocated ribs. Its killing me not being able to set the Cummins in and see how the mounts I got from you turned out!!!!
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Unread 12-05-2011, 02:58 PM   #13
RobsCrawlin7
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i will be following this. i dont ever plan on adding ac to my cj, but my buddy is.
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Unread 12-06-2011, 05:13 AM   #14
youngjeeper11
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Heres some pics, no particular order,
wp_000296.jpg   wp_000297.jpg   wp_000298.jpg   wp_000299.jpg   wp_000300.jpg  

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Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

Ask me about my 4BT Cummins Motor Mounts!!
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Unread 12-06-2011, 05:14 AM   #15
youngjeeper11
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In the last two pics you can see where I need to cut a hole in the firewall for the heater and ac lines, but there is already a indentation in the firewall where it needs to be.
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Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

Ask me about my 4BT Cummins Motor Mounts!!
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