258-AX15-D300 Swap - JeepForum.com
Reply
 
LinkBack Thread Tools
post #1 of 157 Old 04-24-2015, 06:13 AM Thread Starter
orange150
Registered User
1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 868
258-AX15-D300 Swap

Yesterday my T5 started knocking, so it sounds like I'm going to have to do what I didn't want to do and swap the AX15 in before I do the 4.0 swap.

My current set up is 4.2/T5/D300 w/ power brakes.
1995 AX15 is an external slave unit.

I'd like to run through the parts list to make sure I have everything covered:
  • New pilot bushing. From Novak
  • Clutch kit, from auto parts store. Does it matter what year? Can I use the 4.2 flywheel?
  • D300 adapter/clocking ring. Advance or Novak, is there a preference?
  • D300 shift linkage. Novak recommends using the Currie unit since it is 'adjustable'. What is your take on that?
  • Trans mount. I'm thinking about getting someone local to make a cross member, but that is merely a thought right now. Are any of the adapters (such as Novaks) worth getting?
  • Drive shafts will need to be altered

Here's my biggest gray area:
  • Pedal Assy. What needs to happen here?
    There is a local guy with a pedal set from an '87 YJ. Can I run that assembly with the stock late '90s external slave/master hydro plumbing? Again, Novak sells a hydro setup, but the beauty of converting the pedals would be I can get parts from any parts store..
  • Hydraulics. That will build off of the pedal conundrum. The late '90s hydraulics come as a pre-bled unit from the parts store.

There's the start of this process. Let me know what y'all think on that list.

And since I mentioned it so much, Novaks page on it:
http://www.novak-adapt.com/catalog/a...550_to_amc.htm

This keeps coming up in a google search: http://www.cj-8.com/forum/showthread...-15-conversion

Attached Thumbnails
IMG_0303.jpg   IMG_0265.jpg   IMG_0266.jpg  

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
orange150 is offline  
Sponsored Links
Advertisement
 
post #2 of 157 Old 04-24-2015, 10:21 AM
jeepwhore
Registered User
1984 CJ7 
 
Join Date: Jun 2006
Location: Kamloops
Posts: 4,127
There are mounting differences between the early and late YJ clutch masters. Unless you want to alter the firewall I'd use an early YJ master. I would also match the clutch to the transmission, not the engine. The CJ flywheel will be fine but is it worth it to have it re-surfaced? You have to take it off anyway, might as well put the 4l one on so everything behind the engine is matched like it would be behind the 4L.

'84 CJ-17: 17" stretch, locked Toy axles, 5.5" lift, FI, AX15, D300 w/twin sticks, boatsides & junk.
jeepwhore is offline  
post #3 of 157 Old 04-24-2015, 11:41 AM Thread Starter
orange150
Registered User
1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 868
Ok, so it sounds like I can use the local guy's '87 YJ pedal assembly, but, I would have to use an early YJ master with a late 90s slave? And if I did that, could I swap to a YJ brake booster?

Complete flywheel/clutch assy for a '96 4.0l Jeep. That's easy enough

Hey! The wife and I will be in Kamloops for two, non consecutive evenings in June! I might PM you for some dinner recommendations!

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
orange150 is offline  
 
post #4 of 157 Old 04-24-2015, 01:58 PM Thread Starter
orange150
Registered User
1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 868
If I wanted to do this cheap and dirty, could I reuse my existing flywheel and clutch assy?

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
orange150 is offline  
post #5 of 157 Old 04-24-2015, 02:56 PM
RenoF250
Registered User
1985 CJ7 
 
Join Date: Sep 2011
Location: Reno
Posts: 2,655
Quote:
Originally Posted by orange150 View Post
If I wanted to do this cheap and dirty, could I reuse my existing flywheel and clutch assy?
What size pilot shaft is on that trans? The smaller one can use the 258 bushing. You can use the flywheel regardless. The clutch is slightly different so you need to get the 4.0 clutch now. There is no reason to take the flywheel off the 258.

I used the stock xfer case shifter and bent it with the torch. Came out right where it was before with a couple bends.

I used the pre-bled hydraulic, not sure what year my pedals were from. Had to put CJ brake pedal on the new assembly.
RenoF250 is offline  
post #6 of 157 Old 04-24-2015, 07:41 PM
ThisGuyUKnow
Registered User
1985 CJ7 
 
Join Date: Jul 2008
Location: Mobile
Posts: 943
Quote:
Originally Posted by orange150 View Post
If I wanted to do this cheap and dirty, could I reuse my existing flywheel and clutch assy?
Advanced adapters sells a nv3550 adapter plate to mount the ax15/nv3350 to an early YJ. If you buy the plate you can measure, remove one of the studs and relocate it to match the original CJ tranny mount. Then you can bolt it all to the stock skid plate with no modifications to it. You have to use the rear skid plate position.

You cannot reuse your CJ shift linkage the Ax15 is hydraulic and setup for that. If you want it to fit right( aka not look like crap) you need to use an early YJ clutch master. It is the correct size and width to fit in the location stamped out on your fire wall that was used with the 4 cyl CJs. What you will need to do is go to a custom hydraulic shop and have them make a hose to with the correct connection for the early master and the external slave.

I recommend also using a an early YJ pedal assembly as opposed to trying to modify the CJ7 clutch pedal.

I would also recommend using the 4.0 flywheel. Solely because you will have it all apart anyway and although it may not be in your cards at the moment this opens you up to have the ability to go to the 4.0 injection at a later date. You will have the correct flywheel and the location to mount the CPS sensor and it will save you about 400 or more bucks on the relocation unit.

1985 CJ7 Laredo, 4.0, NV3550, D300, 3.31 AMC 20 w/trac loc
ThisGuyUKnow is offline  
post #7 of 157 Old 04-25-2015, 09:42 PM
RenoF250
Registered User
1985 CJ7 
 
Join Date: Sep 2011
Location: Reno
Posts: 2,655
Quote:
Originally Posted by ThisGuyUKnow View Post
Advanced adapters sells a nv3550 adapter plate to mount the ax15/nv3350 to an early YJ. If you buy the plate you can measure, remove one of the studs and relocate it to match the original CJ tranny mount. Then you can bolt it all to the stock skid plate with no modifications to it. You have to use the rear skid plate position.

You cannot reuse your CJ shift linkage the Ax15 is hydraulic and setup for that. If you want it to fit right( aka not look like crap) you need to use an early YJ clutch master. It is the correct size and width to fit in the location stamped out on your fire wall that was used with the 4 cyl CJs. What you will need to do is go to a custom hydraulic shop and have them make a hose to with the correct connection for the early master and the external slave.

I recommend also using a an early YJ pedal assembly as opposed to trying to modify the CJ7 clutch pedal.

I would also recommend using the 4.0 flywheel. Solely because you will have it all apart anyway and although it may not be in your cards at the moment this opens you up to have the ability to go to the 4.0 injection at a later date. You will have the correct flywheel and the location to mount the CPS sensor and it will save you about 400 or more bucks on the relocation unit.
You do not need to go to a hydraulic shop. I bought the master slave unit that is connected and pre-bled, works great.
RenoF250 is offline  
post #8 of 157 Old 04-25-2015, 10:42 PM
jeepwhore
Registered User
1984 CJ7 
 
Join Date: Jun 2006
Location: Kamloops
Posts: 4,127
The pre bled all in one units are for later models. The '87 pedals he wants to use have a different size post to connect the master and the firewall mounting is different. Not an insurmountable difference, but when mine goes In I am going with a separate master and slave with a normal flare ended line. The longevity of the slaves these days isn't the greatest and I'd rather only replace one part at a time than the whole thing.

'84 CJ-17: 17" stretch, locked Toy axles, 5.5" lift, FI, AX15, D300 w/twin sticks, boatsides & junk.
jeepwhore is offline  
post #9 of 157 Old 04-25-2015, 11:29 PM
ThisGuyUKnow
Registered User
1985 CJ7 
 
Join Date: Jul 2008
Location: Mobile
Posts: 943
Quote:
Originally Posted by RenoF250 View Post
You do not need to go to a hydraulic shop. I bought the master slave unit that is connected and pre-bled, works great.
I am not flaming you do please don't get offended :This response shows that you either did not read what I said completely or you do not understand what I am saying.

The later cj fire wall is pre stamped for a hydraulic clutch mc. The early yj mc matches the dimensions for this stamp.the early yj mc was never paired with the later external slave cylinder used in the ax15/nv3550 trannies.

The later mc that was used has a larger bolt spacing and does not match the dimensions of the stamped section of the fire wall.

Can you buy a pre bled it factory yj mc and slave setup from a later yj? Yes you can and it will work correctly, however if you care about the fit and finish if the project and you want it to look right, you will need to use an earlier yj mc and have a custom hose made to work with the external slave. The earlier mc will correctly fit the fire wall in the pre stamped location.

1985 CJ7 Laredo, 4.0, NV3550, D300, 3.31 AMC 20 w/trac loc
ThisGuyUKnow is offline  
post #10 of 157 Old 04-26-2015, 07:57 AM Thread Starter
orange150
Registered User
1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 868
Alright, just bought the '87 YJ pedal set. I'm going to do the early YJ master to fit the CJ firewall, '95 slave to fit the trans, and make a hydro line.
I'm also going to do the '91 flywheel to match my 4.0 that I have, and '95 clutch to match the trans.

One thing while I have the 'new' pedal set. Can/should I upgrade to YJ brake master cylinder?

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
orange150 is offline  
post #11 of 157 Old 04-26-2015, 08:30 AM
ThisGuyUKnow
Registered User
1985 CJ7 
 
Join Date: Jul 2008
Location: Mobile
Posts: 943
Quote:
Originally Posted by orange150 View Post
Alright, just bought the '87 YJ pedal set. I'm going to do the early YJ master to fit the CJ firewall, '95 slave to fit the trans, and make a hydro line.
I'm also going to do the '91 flywheel to match my 4.0 that I have, and '95 clutch to match the trans.

One thing while I have the 'new' pedal set. Can/should I upgrade to YJ brake master cylinder?
You could if you wanted to. It's really up to you and if you feel your current booster isn't packing enough punch.

. If you want I have a booster and bracket from 91 and I have one of the adapters you need for the lines. I wasn't planning on using them.

1985 CJ7 Laredo, 4.0, NV3550, D300, 3.31 AMC 20 w/trac loc
ThisGuyUKnow is offline  
post #12 of 157 Old 04-26-2015, 08:46 AM Thread Starter
orange150
Registered User
1982 CJ8 
 
Join Date: Apr 2014
Location: Raleigh
Posts: 868
Is there a performance reason for swapping? I was under the impression that the YJ master was a better unit..

'82 CJ-8
258/AX15/D300
OME YJ 2.5"/31s
D30/D44/3.73s/Truetracs
orange150 is offline  
post #13 of 157 Old 04-26-2015, 09:11 AM
ThisGuyUKnow
Registered User
1985 CJ7 
 
Join Date: Jul 2008
Location: Mobile
Posts: 943
Quote:
Originally Posted by orange150 View Post
Is there a performance reason for swapping? I was under the impression that the YJ master was a better unit..
The yj booster is supposed to be more powerful. If I were you I'd do some research and decide what route to there. I'd say yes it is worth it but it's just an opinion. The holy grail of yj booster swaps is the dual diaphragm booster which is next to impossible find for a reasonable price.

I didn't use the single yj booster I have now because I had a buddy modify tj dual diaphragm boosters push rod and installed it in my cj7 instead

1985 CJ7 Laredo, 4.0, NV3550, D300, 3.31 AMC 20 w/trac loc
ThisGuyUKnow is offline  
post #14 of 157 Old 04-26-2015, 10:40 AM
jeepwhore
Registered User
1984 CJ7 
 
Join Date: Jun 2006
Location: Kamloops
Posts: 4,127
You will have to weigh the options and choose which is easier for you. If you keep the stock booster you'll either have to modify the YJ brake pedal or your CJ booster push rod. The alternative is to get a booster that matches the pedal assembly. Note that the '87-'90 YJ's have a different booster than those with the HO 4L so I don't know if the '95 dual diaphragm would be a bolt up swap with your '87 pedals. I can't confirm if the push rods are different lengths between the YJ boosters but on rockauto there are different part numbers that don't cross between the two. The early YJ booster doesn't share part #'s with the CJ either so I'd have to assume that some modification of the push rod would be needed.

'84 CJ-17: 17" stretch, locked Toy axles, 5.5" lift, FI, AX15, D300 w/twin sticks, boatsides & junk.
jeepwhore is offline  
post #15 of 157 Old 04-26-2015, 10:47 AM
jeepwhore
Registered User
1984 CJ7 
 
Join Date: Jun 2006
Location: Kamloops
Posts: 4,127
Looks like the '95 push rod is 1/4" shorter and the hole in the push rod needs to be drilled bigger to fit the '87 pedals. This guy didn't alter the push rod:

http://www.jeepforum.com/forum/f12/9...grade-1287758/

'84 CJ-17: 17" stretch, locked Toy axles, 5.5" lift, FI, AX15, D300 w/twin sticks, boatsides & junk.
jeepwhore is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome