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Unread 09-07-2012, 12:03 PM   #31
MattGATRTJ
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1999 TJ Wrangler 
 
Join Date: Jan 2008
Location: Braselton, GA
Posts: 476
Its been pretty enjoyable. Took a long lunch today and definitely avoided all short cuts

Its definitely got more go than ever before, not insane feeling, but will definitely sit you back in your seat. I am still trying to get used to have an automatic transmission. Takes some fun out of it, but will be better offroad.

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Unread 09-08-2012, 04:37 AM   #32
chmo
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2006 TJ Wrangler 
 
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Location: Abu Dhabi, United Arab Emirates
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@MattGATRTJ: keewwl

Today Saturday update :
Sluggy went to the exhaust shop ... on a recovery truck. (loud, untested I thought it is safer like this)

Tomorrow we will know more
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Unread 09-14-2012, 02:48 PM   #33
chmo
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wednesday update :

- alternator connected ... (hopefully charging )
- fan at the moment temporarily "full time on"
- exhaust done


- workshop did test drive ... automatic still in safe mode not shifting ... eventually VSS sensor on outputshaft needs adjustment
I am jealous ... I came after the test drive and they were already disassembling something ... one of my friends says POWER ... and if he says this ... (he offered me already to buy the car after me eventually crashing it... grrrr)
- transfer case shifter cable modified to reach all positions

oh ... and I heard the engine running ... sweeeet tone from the exhaust ... deep and not too loud ... V8 like

I offered the workshop guys to do some work on Saturday myself! (park/neutral switch , backup light, tach emulator, brake/TCC lock out switch ... they are a bit helpless regarding the OE 2006 TJ wiring )

going to need a medium coolant overflow bottle/canister to be mounted on the driver side tray under the brake booster ...
... and the O2 sensor connectors require US spec square plugs instead of the wide ones usually available here ... sigh
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Unread 09-15-2012, 04:06 PM   #34
chmo
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After me spending one day in the workshop ANOTHER SIGNIFICANT PROGRESS REPORT:
(yeah ... electrical extras are not really 7p's favorite job! So did it myself )

modified the Jeep pcm harness to accept the tachometer/RPM signal from the GM computer!
Here you can see the original jeep gauges working properly ... including the RPM gauge ... yesss
tach_oe.jpg
stepping a bit on the throttle ...
need to figure out how to disable some stupid "check engine light" and "check gauges" from the jeep computers

all what was needed was the little Novak black box called tach emulator to convert the GM rpm signal to a Jeep crank shaft position signal:
tach_emu.jpg


- another important step: finally got the fan controlled by the GM computer as Fan#1 ... had to do some smart programming myself to ignore missing A/C pressure signals and to adjust speedo thresholds as well

- coolant overflow bottle: managed to reuse the original Jeep coolant overflow bottle by choosing a smart location where it still fit ...
washer_b_placement.jpg

- connected the brake/TC lock out signals to the original jeep brake switch ... by cutting out the cruise control lines there (pin3 and pin4) and reusing the switch to interrupt 12v when pedal is pressed to unlock Torque Converter ... easy peasy

- routed pin 6 (Backup Light Signal!) from the original jeep auto transmission connector (10 pin 42RLE transmission range sensor connector) from under the tub to the cabin to be connected to the Lokar shifter sensor Backup Light signal

- Sahara did a nice exhaust job with the parts I supplied ... the "only" thing they had to do was to bend some tubes from the headers to the Magnaflow Y pipe (well they forgot the sensor bungs ... then did some completely useless bungs at the backside of the Y legs ... then 7p fixed it) then to weld the moroso spiral flow resonator and then the Magnaflow 12589 Muffler and then the ready made 3" afe tailpipe together and to fabricate some hanger brackets ...
note the nice flex pipes which Sahara put there on my request!
exhaust_2ypipe.jpg
ypipe_magnaflow.jpg
moroso_support.jpg
how it sounds? aaawwwwsomme ... quieter than so many borlas out there but with a subtle and deep V8 rumble

- The right upstream O2 sensors have been mounted by 7p at the new mounting bungs below the headers!

- Transfer Case shifter cable modified ... Shifter adjusted by 7p!

- VSS speedo sensor adjusted by 7P, the transmission now shifts correctly!

- The Derale transmission cooler with fan came with a temp switch ... here is the location directly at the transmission housing:
(sorry for the blurry pic!)
still testing if it will turn on as planned
derale_tempswitch_4l60e.jpg

- cleaned up the engine compartment to hide as many as possible "naked" wires in the right plastic looms

- tested the HVAC controls ... all working! (vacuum for the blend doors and fan speeds)


Still to do:
- Lokar CIND gearshift decoder and indicator need to be correctly mounted/adjusted/wired up!
- Dashboard and cabin needs to be cleaned up ... the center console and the shifter boot ... etc ...
- A/C work !!!!

AND THEN ... FUNNNNNN
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Unread 09-16-2012, 03:49 AM   #35
chmo
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The drool Video

soundcheck
(for the uber experience headset recommended ... and a towel )

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Unread 09-16-2012, 08:15 AM   #36
nshefbuch
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Great build. You've done a nice job on the swap. What mufflers are you going with? Also, hope the stock axles hold up for you.

Edit, just saw you have mags 3".
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Unread 09-16-2012, 09:40 AM   #37
chmo
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Quote:
Originally Posted by nshefbuch View Post
Great build. You've done a nice job on the swap. What mufflers are you going with? Also, hope the stock axles hold up for you.

Edit, just saw you have mags 3".
Thanks!
I was just going to quote myself

Re "stock axles"
both the D30 and the D44 have chromoly axle shafts ... The D44 is going to get a superior super truss to reduce torque flexing.
The LS1 is "untuned" (with stock Holden tune) at about 300hp/330lb.ft ... and will stay like this as long as transmission and axles are not built further
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Unread 09-16-2012, 10:41 AM   #38
nshefbuch
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Quote:
Originally Posted by chmo

Thanks!
I was just going to quote myself

Re "stock axles"
both the D30 and the D44 have chromoly axle shafts ... The D44 is going to get a superior super truss to reduce torque flexing.
The LS1 is "untuned" (with stock Holden tune) at about 300hp/330lb.ft ... and will stay like this as long as transmission and axles are not built further
Sweet. Untuned but will it still pull decent mpg on highway?
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Unread 09-16-2012, 12:28 PM   #39
chmo
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Quote:
Originally Posted by nshefbuch View Post
Sweet. Untuned but will it still pull decent mpg on highway?
Don't know yet.
I am still running the stock maf sensor and IAT and the upstream O2s ... so I am confident it is at least not going to be worse than stock. Well ... except that I am running 4.88 with 33x12.5's ... the same gear to tire ratio as stock would have been 4.10 with 33's. So I am a bit lower in ratio.
(originally on the Holden it was 3.07 (or 3.26?) with light and tiny ~28" tires for street use )
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Unread 09-16-2012, 05:15 PM   #40
Heliandrew
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its looking good
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Unread 09-17-2012, 03:39 PM   #41
chmo
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Quote:
Originally Posted by Heliandrew View Post
its looking good
Thanks!

Ok ... one more update ... tried to adjust my gear shift indicator with sensor kit and decoder box (Lokar CINS 17002) yesterday.
It would have been real nice to hook up my backup lights and my park/neutral wires to the box besides a working gear display.

BUT: somehow a small spring coming with the kit is not there anymore ... lost?
And the small set screws for the sensor cable fixing are a real PIA...

SO ... decided to take the Lokar CINS stuff apart ... that stuff seriously needs some mods/improvements.

annnd ... finally managed to dig out a FSM for my 2006 TJ ... nice wiring diagram for the AC/Heater control and nice PCM pin outs for the newer 4 plug Jeep PCM.
Now I have a very clear plan how to hook up my Sanden FLX7 A/C compressor bypassing the non existent (anymore) pressure switches and telling the GM PCM at the SAME time when the compressor clutch engages.
Will turn on GM PCM conrolled Fan#1 (my Spal fan) as well ... automatically ... YESSS!

Will do the Lokar CINS stuff later ... the A/C has taken precedence
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Unread 09-18-2012, 12:53 PM   #42
chmo
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Sluggy babe is sleeping at home tonight :mrgreen:
The lucky parents took the little one this evening back home after some basic checkup.

A first test drive by me unveiled a slight rub of the steering linkage in some circumstances.
Dr. Hisham found the linkage to be rubbing against the radiator mounting bracket in the front ... and against the powersteering pump fitting which was slightly leaking as well.
Additionally he found a small coolant leak at the lower radiator release fitting.

So
- radiator relocated slightly
- power steering pump fitting grinded until penetrated ... then copper welded and smoothened to close the new leak :roll:
- radiator fitting rethreaded in with some teflon tape
- all tightened up real snug.

Then I took Sluggy for a 30 minutes ride home ... fast and then slow in city traffic.
Steering was great ... cooling was great below 210*F (100*C)... transmission oil temp stayed below 160*F all the time as well ...both fans (rad and transmission cooler) were cycling nicely! 8-)
Tomorrow then first thing in the morning I need to check for coolant and transmission oil spot below the parked car ...hopefully Sluggy is dry then :lol:

Other than that : it IS a different beast now ... scary at the beginning ... demanding respect later. And a deep low V8 rumble reminds me all the time : no need to stomp on the throttle ... a slight massage is plenty enough! :twisted: :mrgreen:

For sure some more slight child deseases might pop up later ... but I am optimistic

A/C and shifter indicator sensor still pending ... but soon!
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Unread 09-19-2012, 12:50 AM   #43
chmo
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I need a new fitting at the power steering pump!
(Sluggy still needs diapers)

Fortunately the radiator is fine now ...
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Unread 09-21-2012, 07:09 AM   #44
chmo
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found a new AN-10 to hose elbow on my unused PSC steering fluid reservoir ... YESSS ... tomorrow I will try it if it will clear the steering rod.

on the way to the office yesterday my coolant was splashing all over the engine bay. A quick check showed me that the steamport hose coming from the TB to the radiator was pressed down by the air intake tube and touching the waterpump pulley (the price you have to pay if you let someone else do the work ... you have to double check and eventually fix )

after work I removed the steamport/TB heater hose ... and yes IT WAS EXREMELY rubbed by the waterpump pulley and punctured.
cut the punctured part off and tried to route from above the air intake tube ... too short.

so ... at 16:30 a emergency call to a very dear and very close friend who recently got a new job as workshop manager at a well known premium car showroom here in AD.

30 minutes later I was holding a 50cm high pressure ASE100 1/4" hose in my hands.

10 minutes later I had the hose cut to lenght, mounted correctly, coolant refilled (I had lost HALF a radiator coolant without over heating, goooood )

one small hickup in town ... would have screwed a desert trip for sure

back home ... and from Thursday morning till now I have made 150kms in town with some fast sections ... and still half a tank full ... seems like mpg is 50% better than with the 4.0 I6L
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Unread 09-26-2012, 04:18 AM   #45
chmo
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A/C:
is getting installed by a "specialist"
Took them 2 days to get all the small fittings and dryer/mounting options and the piping figured out.
Now they supposed to have all prepared and wiring started to have all controlled as if it was a Jeep A/C

Backup Light/Park Neutral/Gear shift indicator sensor/decoder:
theoretically all figured out ... but waiting for the A/C to finish to pour the info to the poor workshop guys.
THEN registration renewal ... next week?

Drivetrain and more upgrades: ()

Bilstein 5160 remote reservoir shocks for TJ 3" lift supposedly on the way from Kolak (after 3!!! months back order) BUT

complete set of 8 currie adjustable Johnny Joint control arms plus
Anti-Rock torsion anti sway bar plus
currie JJ front axle upper housing kit plus
currie JJ front and JJ rear adjustable track bars plus
limiting straps plus
LED tail lights plus
LED flasher relay plus
black low restriction 3D mesh grille insert
all picked up from brown UPS santa today

With my ready waiting Superior Super Truss for the rear D44 and
my bolt on T&T rear upper spring plate relocators (here as well) and
my planned prothane coil spring inserts stage 2 reengineered and fabbed

I think not much more doable (bolt on, street legal HERE!) anymore most compromises eliminated
(except ... it still is no King shocks, no new Savvy modular UA yet, no Dana 60's, no "eat my shift" race transmission )
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