[Tim]

well, just a few pics today. dad came up and we slid the transmission right in once we figured stuff out. now i am getting pretty excited about this thing.

it turns out that the hole used for the shift cable has been used by me in the tj's early days.. lots of wires getting re-routed... yay... well, now is as good a time as any to erase the rest of my wiring sins from way back. it's not terrible, but can use some help. everything under the hood will finally be consolidated. i also had to re route the mechanical gauge lines.


theres the driveplate and spacer installed and torqued. i used some red thread locker on these bolts.


getting things ready for install. this jack worked pretty good. it is hard to start lifting but once it is up three or four inches it gets easier...


took a pic of Dome doing my dirty work while i was grubbing


all lined up... i only have a lot to do now


one last look from the top...

more next weekend

[That1guy]

No love for the AX15?

[That1guy]

double post.

[Tim]

actually got off work a tad early and had some time to do a few things with wires. all the conduit is coming off previous wiring jobs and everything is going together in an orderly fashion (or else)

tonight my main focus was wiring up to the plug above the tranny for the reverse lights, laying in the harness i made and stripping back the pcm plug sheathing. this part is right up my alley...


here is the plug for the reverse lights. following stu's advice i had wired into the harness before installing the tranny so all i had to do is clip off the loop on the plug and the v/w wire. the remaining one was used...


i found two sets of terminal probes at a garbage sale last spring, this conduit ripper comes in real handy.


i tested the wires to make sure they matched my cheat sheet. it really helped me wrap my pea brain around what i needed to do. i used stu's wiring pages, the 97 tj FSM, 2000 xj fsm and some other write-ups found on stu's site to check and double check my work.

the multi colored wires hepled me quite a bit and i suggest anyone that plans on doing this to get several shades. when i had a dupicate color i would take a black sharpie and run a line down it.

it turns out that my harness is plenty long enough. i did a little back tracking and revised the harness a little, it was easy to do... also, i decided i would solder directly to the tj harness instead of using plugs.

some of the length will be kept to make future mods to the harness more simplified.

[Tim]

okay,

the transmission wiring is done and i have got most of the rewiring done. i still have to mount the cooler and wire its fan too. i am hoping to have the remainder of the wiring done tomorrow sometime.

i decided to put the clayton cradle up to see what is in store for a mount, here's some pics so you guys can scratch your noggins along with me


frontal


backal


p-sideum


bottomary

i need to see what a xj mount looks like before i decide what to do. i dont know if it will fry the rubber.... but, i was thinking of welding to the tj mount. some flat bar on each side and or front may do the trick.

or....

throw the mount on a plate, draw a line around the front and sides, cut it out and weld it...

or...

bolt a plate on top of it like everyone else...

there-ya-go..

[Tim]

busy day outside of the garage, but i did get some stuff done like the new keyed fuse block.


i cut it down a bit for clearance


here it is installed with a direct power line from the battery that is fused and relayed. it is triggered from another keyed circuit. the cooler fan and the new gauge are the first to be connected here.


i was looking for a way to mount the cooler on rubber mounts. ace hardware had these rubber bushings that fit perfectly. si spray made them go in without too much trouble.

also, i finally had time to pull the pan. i was quite pleased to see clean very magnets and juice in the new juice box! well, it only had 20k on it everything inside looked super clean.

one more thing, my center console (newer 2pc style) does not seem to be fitting right. i wound up with a xj shifter so the console mount is not the same.. DUH!!! it will be an easy fix with a piece of angle and a zap.

time to reset the garage for the next round. funny how trashed it gets every day...

[Tim]

installing the temp sensor.

i havent tried to braze in at least 20 years. i cleaned it up real good first.. i hope it holds...

[Tim]

thanks guys it's been a busy weekend so i didnt get a lot done. i revised the brake pedal again. i decided it stuck out too far and ditched the xj pedal. it was easy enough to swap over the tj one i had in there before. sitting in the drivers seat and trying it out i have decided that i like it even better than the wide pedal.

i also completed the interior part of the swap. i had to make a bracket extension for the center console (xj shifter vs tj console). i haven't heard of anyone having this problem but it was an easy enough fix.

the whoredome of pix continues.....

below are some comparisons of brake pedals:


you can see the tj 5 speed version is lower and longer than the xj


if i did not have the xj pedal i would not have the bushing you see here to make the pedal work by itself. you cannot simply remove the clutch pedal as the clutch and brake pedal for the 5 speed are not bushed. if i did not have the xj brake pedal i would have cut the clutch pedal off at the pivot to get this effect.


installed in the xj bracket with the xj bushing...


here is the bracket i made to anchor the console.


test fit. i used a piece of the tj brake clutch combo bracket to make it.


there it is all together...
the green led tells me that the cooler fan has power from the switch on the dash top pod. the red led tells me when the fan comes on. i think i made very good use of an airbag switch that i never hooked up...

[Tim]

got just a little time in today on the jeep. didn't get a lot done but did take some pics...


this is half the mount for the powered cooler. it mounts to the rear footwell wall with two bolts. i welded nuts for the mount and welded bolts to go through the rubber fan mounts.


from inside the tub with fender washers.


underneath...


mounted up... the rubber bushings will help preserve the cooler if there is any tub flexage.. i put caps on the an fittings to protect them and keep any junk out while i fumble through this..


B&M says to use anti-sieze on the threads to prevent gauling. also use two wrenches to tighten the fittings in unless you want to quickly ruin the cooler.

[That1guy]

Is it a good Idea to put the cooler down there instead of under the hood? If you went into a mud hole or something. I could see it tearing up the fan.

[sourskittle]

Hey man, keep'em coming !!! Looks great so far !!! I always thought the AW4 was "way way too big" and that's why jeep never used it in the wrangler. Looks like it fits as nice as a V8 does

I like the pics too. Good shots. I bet its going to be pretty nice...

Wonder if I can adapt a 5.0L ford to an AW4... Ok... Its getting complicated now

[Tom Hartz]

[QUOTE=sourskittle;6063225]Hey man, keep'em coming !!! Looks great so far !!! I always thought the AW4 was "way way too big" and that's why jeep never used it in the wrangler.


I was thinking the same thing. I may have to do this to mine. Please let us know the price of the complete project when you can. I am also looking at the Stak 3 speed transfer case with overdrive.

Tom

[Tim]

there is noend to my picture whoring capabilities

right now i am rethinking my tubing/flexable hose. i have a plan in mind now that should work nicely.

the shafts from tom woods should be here the first of next week if they dont show tomorrow. i am not in a terrible rush. the front will be a heavy duty long splined shaft. ther rear one is also their heavy duty version that i bought six years ago.

other than that it is just one more cooler to mount and some odds and ends. realisticly i will be able to fill the system and fire it up.... i wont be going anywhere tho needum shafts for that...

i will try to talley the price for everyone and there will be plenty more pictures for the internet to choke on

[Tim]

tom woods came through and got the rear shaft to me really fast. that was unexpected!!! he said it would be here next week. looks like i have enough stuff to plumb everything too.

the front shaft should be here next week from tom wood's. got a busy weekend, hope i can get it out for a drive!

[Tim]

well, not much progress today but there was some

went to the Dr. and got cleared finally for going back to work... the light duty was a real bummer... i asked the doc if i can climb a rope now, he laughed at me and didn't answer.

also, some friends i made on the natches camping trip stopped by today and we talked jeeps for a while. so far my day is very enjoyable.

good friends, good news... good food

progress...

i went ahead and used hose for the whole thing. i still want to do some hard line in there but it's just too much of a strain right now to reach up there and try to bend stuff. i plan on bending the tubing the way i want it at my leisure and then install it later.

more good news, the rear drive shaft fit perfectly, this is getting real now.

semi-bad news.... the exhaust. it is so close to the rear 90 -6 an fitting. i can just fit my finger between them. realistically i don't think it is a terrible thing but still, i don't like it.

tomorrow...
-fluid (wonder how much that's gonna take??)
-recheck bolts
-exhaust hanger relocation
-rear pinion angle
-air intake
-who knows what else.....

pics for those interested:


front view of the small cooler. i had it positioned elsewhere but this area seemed to be the best. i welded some 14 gauge plate onto the clayton cradle, there are nuts welded onto the back of each one. too bad i wasn't thinking right or i would have just tapped the holes...


the rear cooler... i had to 45s for this one. 90s would have been better but i didn't know exactly what i wanted so i got two of each from summit. it worked out okay i think. i also bought two straight ones.


some trick photography... looks like a brush knife in that pic, huh? it cut through that hose like it was nothing.

hopefully i will have more to show tomorrow...