V8 5Speed Swap conclusion, sort of.

S C · 10-09-2006, 02:36 PM

So this past week I attempted the 5 Speed swap on my 5.2L ZJ. Long story short everything didn't fit like I intended, so for now I put all my old stuff back in.

Here's some notes for anyone else who attempts this swap.

I used an NV3500 out of a 2000 Dodge Dakota V6 with a 231D.

The starter pocket is on the wrong side, of the bellhousing, I thought it might be able to squeeze in, but the exhaust manifold is to close, and the upper suspenion arm will contact the starter at ride height.

I made another stupid mistake, and didn't take into account the tone ring on the V6 has a different number of notches then the V8, so I got a V8 flywheel and clutch.

This is another major issue, the crank on the 5.2 does not come machined for a pilot bearing. Its a few thousandths off, I drilled out the extra material with a 1" bit, the pilot bearing is exactly 1" in diameter. The bearing pressed in, but was not as tight as it should have been, so when I try this again, we'll make a couple tig tacks to hold it secure.

The crossmember needs to be moved forward since the V6 trans is not as long, not really a big deal.

The pedals will need modification unless you happen to find a V6 Grand which is hard to find. The YJ pedals I have are going to take a bit of modification to fit.

I think those were all the major issues, just about everything that could fight me on this project did. I'm tired, that auto trans is HEAVY.

Also, the CPS from the auto is to long, you'll need a V8 Manual CPS, for some reason they decided to make the tone rings a .25" different....

GM's are so much easier for this sort of thing, everything interchanges so much easier.

MSU.WJ · 10-09-2006, 03:41 PM

Why did you go with the NV3500 and not an AX15 or AX4 or something equivalent that was actually used in other jeeps?

anticrombie · 10-09-2006, 03:53 PM

Quote:

Originally Posted by MSU.WJ

Why did you go with the NV3500 and not an AX15 or AX4 or something equivalent that was actually used in other jeeps?

Ax15 won't mate to the 5.2.

S C · 10-09-2006, 04:53 PM

the AX 15 isn't as strong as the NV3500 as well.

**EMTimZJ** · 10-09-2006, 05:47 PM

Quote:

Originally Posted by anticrombie

Ax15 won't mate to the 5.2.

Woody suggested that it should work with a Dakota 3.9L bellhousing.

If you get a fly wheel with 8 evenly spaced notches you can use the stock CPS sensor if you make a small spacer. I ran into this too after I put on my flywheel.

EDIT: I goofed! The Jeeps use the NV3550! Thankyou!

Also, my pilot bushing pressed right in just fine... I wonder if there was a change made in the end of the crank fron '94-'97

It was the pilot bushing that came with my Luk clutch kit.

S C · 10-09-2006, 06:01 PM

we tried the pilot bushing in the 5.2 in my jeep and the 5.9 that were in the shop, the 5.9 had an even smaller hole.

S C · 10-09-2006, 06:11 PM

Tim, I just looked at your build thread, is that a brass pilot bushing in your crank? I recieved a roller bearing pilot bushing.

**Woody** · 10-09-2006, 06:18 PM

Tim, Jeeps didn't use the 3500, they used the 3550.

Also, I thought I told everyone that YJ pedals won't work. XJ pedals work in the ZJ bracket, and that's about it.

I didn't think about the starter location. Hmmm....which side of the 5.2L is the starter on in a Ram? That bellhousing should work as well.

S C · 10-09-2006, 06:32 PM

The YJ pedals will work, I'm not to worried about it, though if i stumble upon a set of XJs I'll pick'em up, the local boneyards by mean didn't have any though.

I'm not sure which side the starter is on a ram, I won't be able to use that bellhousing though, because the 3500 uses an integral bellhousing, so I'd need to get a whole new trans which would be another money sucker. I figure you can just cut the starter pocket out and rotate it around to the other side, that should do the trick.

**EMTimZJ** · 10-09-2006, 06:50 PM

Thanks for the correction Woody!

The 88-91 Ram bellhousing I have (for the 435) has a driverside starter.

S C · 10-11-2006, 04:44 AM

Tim, was that a brass pilot bushing?

**EMTimZJ** · 10-11-2006, 07:12 AM

Yeah it was

You can barely see it in this picture:

S C · 10-11-2006, 07:32 AM

I'm wondering if thats why the bearing didn't fit, because the bearing I got was a roller. Maybe the brass one was a slightly different size.

**EMTimZJ** · 10-11-2006, 10:20 AM

That is a definate possibility... what is the OD of your input shaft? I'm surprised there was enough clearance for a roller-type pilot bearing...

S C · 10-11-2006, 10:24 AM

i don't know the size of the insput shaft off the top of my head, it fit fine into the bearing. The roller bearing was a few thousandths off, so I drilled it out till it fit.

10-09-2006, 04:53 PM	#4
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	the AX 15 isn't as strong as the NV3500 as well.

10-09-2006, 06:01 PM	#6
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	we tried the pilot bushing in the 5.2 in my jeep and the 5.9 that were in the shop, the 5.9 had an even smaller hole.

10-09-2006, 06:11 PM	#7
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	Tim, I just looked at your build thread, is that a brass pilot bushing in your crank? I recieved a roller bearing pilot bushing.

10-09-2006, 06:32 PM	#9
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	The YJ pedals will work, I'm not to worried about it, though if i stumble upon a set of XJs I'll pick'em up, the local boneyards by mean didn't have any though. I'm not sure which side the starter is on a ram, I won't be able to use that bellhousing though, because the 3500 uses an integral bellhousing, so I'd need to get a whole new trans which would be another money sucker. I figure you can just cut the starter pocket out and rotate it around to the other side, that should do the trick.

10-11-2006, 04:44 AM	#11
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	Tim, was that a brass pilot bushing?

10-11-2006, 07:32 AM	#13
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	I'm wondering if thats why the bearing didn't fit, because the bearing I got was a roller. Maybe the brass one was a slightly different size.

10-11-2006, 10:24 AM	#15
S C Registered User Join Date: Oct 2005 Location: Bristol, CT Posts: 76 Profile Gallery Classifieds My Jeeps	i don't know the size of the insput shaft off the top of my head, it fit fine into the bearing. The roller bearing was a few thousandths off, so I drilled it out till it fit.