[pkavana2]

First off, I want to give a little background of myself. I am a 20 year old college student with limited funds who had a crazy idea to build a jeep. I owned a YJ with a 4 inch lift and 33's for a while but decided that I was going to try to build a custom rig. So I sold my YJ a month ago and started gathering parts.

My basic plan is to build a CJ7 with a 6.2 turbo diesel from a HUMVEE, manual trans (T176, NV4500, C6 havent decided yet), SOA lift, 39 inch tires and Dana 60's. I have read a lot on this forum and it has helped me tremendously so i decided to post my build to give back to the forum but also to get help with the small details of the project.

As of the moment I have front and rear dana 60's from a 91 dodge and 4 39.5 TSL's mounted on 8 lug rims in my driveway. The CJ will be here on Sunday. Its an 85 with no drivetrain. The first step in my project is to pull the axles and swap in the Dana 60s SOA. I have already ground out the perches in the rear and plan to reuse them but narrow the perches to work with the stock CJ mounts. In the front, I plan to outboard the springs because the spring mount is built into the housing. My crossover steering arm came in the mail today and hopefully that will be bolted on tomorrow.

Right now, I need help with the design for the outboard spring kit. I planned on making it myself using 1/4" steel im getting for free. First, I was going to grind off the old spring mounts and try to reuse them in the front and rear. Then, I was going to take a sheet of metal and weld it on the underside of the frame rail, extending outboard to hold the new shackle mount. After that i was going to gusset it with a few triangles welded to the top of the panel of metal and to the side of the frame rail. I could really use some help with this idea though.

Thats my main problem right now. My other issue is finishing up my plan for the drivetrain (toying with the idea of a 700r4 or a TH400 instead of a manual). Also, if anyone could tell me how to put pics up that would be great too. I tried dragging and dropping but that didnt seem to work.

Anyway, let me know what you guys think of this build and I am sure I will have more questions in the future. If anyone lives in the Lower NY area, let me know. I could always use an extra hand.

Pete

[flexncj7]

Sounds like a cool project- I've been contemplating a diesel jeep for years, but time/funds haven't permitted me to do so.
Why a 6.2? the 6.5 turbo is the same size and weight, but the turbo adds more power.
The best tranny for this engine would be either the TH400 or TH700- both will bolt directly to the engine, and adapters are available for the tcase.

I've been thinking of going a different route, using either a Cummins or Isuzu 4 banger.

Good luck and keep posting your progress!

[pkavana2]

I choose a 6.2 that has an ATS turbo on it already plus the market is being flooded with 6.2's because the army is in the process of switching the HUMVEE's from 6.2 to 5.5 diesels. As far as the TH400, I am afraid of the length. I am leaning towards a sm465/np205 but its gonna suck on the highway. I thought about putting a 4 banger diesel from a bread truck in it but they weigh the same amount. This sounds silly that a 4clinder diesel would weigh the same as an 8 cylinder, but I swear they do. So i decided 8 cylinder for more ft/lbs of torque.

[ReconRabbit]

IMHO the 6.2 is a turd, at least in a HUMVEE. It seems like a GIANT pooch. I'm voting the 6.5 also. It sounds like a cool swap though.

[Catrone]

The 6.5 in he humvee is a turd also...they also have a problem with number 8 cylinder wall cracking. Check the casting number to make sure it isn't one of the "bad years"

Adam

[summitking]

Sounds like you have one wicked project started make sure to post some pics when you get stuff done
Do you have the motor? if not i have a article about a 4 cylinder cummins that was made to make 350 hp and still get 28 miles to the gallon and its nice and small and would be easy to fit in
Are you going to run a heavier duty front springs with the added weight of the deisel?

[pkavana2]

in the front i was gonna run heavier springs and i was thinking adjustable shocks but i was gonna call a few companies and see what they suggest.

I do not have a motor yet. I do not know much about the transmissions that were available behind the 4bt. If anyone could help me out I would appreciate suggestions. Also, how do i post pics? I have a ton that i want to share.

[Chrisfol82]

I think the NV4500 would probably fit the 4BT. The 6BT was in dodge trucks and thats the tranny that went behind it in them. I woudl assume the 4BT and the 6BT would have the same bolt pattern but im not really sure.

Its a 5 speed with an overdrive so it would be good for highway too.

[CjinPA]

I am currently looking at prices to put a ctd in an 81 scrambler I just bought. I came across an add on craigslist for a 4bt in the state college area of Pa. The guy wants $800 for the 4bt. Here is the link if you are interested.
http://pennstate.craigslist.org/pts/677137788.html



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[pkavana2]

The problem with the NV4500 is its size and cost. My friend has one and I have been waiting for him to get back to me with a price. Also the gear ratio gap between 2nd and 3rd may be too high for the small powerband of a diesel.

CJinPa, thatnks for the link. I will def look into it. Send me a PM and let me know how close you are to the old PAragon. My friends got a house there if you want to go wheeling in the fall.

[Dutchers]

im also contemplating a 4cyl turbo diesel, actually im most likely gonna do it when i get back and settled in at home so this build up is one ill keep my eye on

[BESRK]

Didn't the NV4500 come stock behind a few diesels?

I believe the Hummers used a T400. Not sure what transfer case though... NP208?

Shoot, with the price of diesel right now, that should help you lever the price of a diesel engine a bit.


I'd like to see a Duramax CJ... that would be fun..

[summitking]

BESRK i have a article on a 6.0 L power stroke powered cj ill try find the link for the vid of it
For your pics joing www.photobucket.com and then load them onto your acount then just copy and paste the img tag from the pics on photo bucket and it will load onto your post and will be resized so it wont take to long to load
Your going to have a wicked project

[BESRK]

I saw a video a while back of a CJ with (I think) a CTD in it... tearing up the dunes. Thing was sick!

[pkavana2]

Thanks for all the feedback guys. I finally loaded some pictures on photobucket thanks to one of the above suggestions. Hopefully these will give you guys a good look at what I've got going.

Here's the jeep when it first arrived Sunday morning





And then with the front clip removed



Few shots of the Dana 60's with the 39.5 inch TSL's. The axles came out of a 91 Dodge Powerwagon. 4.10 gears and the rear is lincoln locked.




Grinding off the spring perches



I will have pictures of the rear axle coming out as soon as I load them. Right now I need to go find u bolts for the rear.