Originally Posted by BHawkmeck View Post
The only solutions I've seen around the forums are to either bring the Sentry Key unit over from the donor vehicle and hide it under the dash somewhere (like this guy did: http://www.jeepforum.com/forum/f12/4...l#post15943545 ),
or find a PCM from a donor that did not have the alarm system enabled.
California 4.0 OBDII Engine Swap
I started this swap about a year and have yet to finish, due to multiple reasons, so I can't comment on fuel mileage or power gains. One of the reason I have not completed this is because of difficulty matting my T-150 to the 4.0. I ended up swapping flywheels and drilling the bellhousing for the CPS sensor which worked out great and once the wiring was right it started right up. The YJ flywheel is thinner that the CJ one and that difference needs to be made up in the throwout bearing. I have tried a few different configurations with parts I had lying around. I ended up modifying the clutch fork and using a Novak slave with a CJ clutch and throwout. I just got it back together last weekend and still need to hook the clutch up to see if this works. Novak has an adjustable throwout bearing that should make this much easier, but I would suggest just swapping in the CJ bellhousing dust shield, flywheel, clutch, throwout and using the CPS relocation kit. This is not my daily driver so I have gone long periods without working on it, but if I was to do this again I would likely go that route. Hope this helps. Jim
I used the T-150 bellhousing that I drilled myself for the CPS, the 4.0 flywheel with a Novak bushing, CJ clutch disk, pressure plate and throwout and a modified CJ clutch fork. The YJ flywheel is thinner than the CJ so the distance has to be made up. As I said, you could probably due it using a Novak adjustable throwout bearing, but I ended up padding out my clutch fork to make up the difference. It's a little ghetto, but it has been working without any problems. I recently realized that one of the problems I had setting the clutch up was due to the Novak slave cylinder. I ordered the 3/4 and they sent me the 7/8 and with the master I was using I wasn't getting enough throw to release the clutch. Jim
Unfortunately you can't just make it up in rod length. If I remember correctly the difference is 7/16 and by the time you make up the length of throw, your clutch fork will not have anymore travel left. I ended up welding 3/8 tube onto the ends of my fork to make it work, like I said ghetto, but it has been working fine. I got the information for drilling the bell housing off of here, but none of the links I book marked are working. I will try and find the information I used, may take a while for me to find it. It's easy to figure out if you have the donor bell housing but I will see what I can find. Jim
If you haven't seen this, it should help. http://www.pirate4x4.com/forum/jeep-...-into-cj5.html if you follow the link to the photobucket page he gives you all the measurements for the bracket. The bracket mounts using the 2 bolts on the upper drivers side of the bell housing. Make the bracket, attach the CPS and then out it up to the drivers side of the bell housing and it will be clear where you need to drill the bell housing. You may need to shim the bracket out to center in on the notched part of the flywheel. I will try and get a picture of mine, but I'm not sure I can get a picture that will do you any good.
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