"Not Guilty II" YJ 4bt build up - JeepForum.com
 
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post #1 of 10 Old 11-11-2012, 12:08 AM Thread Starter
steveo606
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1987 YJ Wrangler 
 
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"Not Guilty II" YJ 4bt build up

All of my adult life I've said "When I run across a good deal on a wrangler I'm gonna buy it and make it awesome." Well that good deal happened to me a few months ago in June. I picked up this 1987 yj with the 4.2 and the blown up peugot (sp?) tranny. With intent to build I set it in the back corner of the garage and started looking for the things I need for this swap. Now theres a Jeep with a pile of parts surrounding it seems like a good time to start a build thread.





So there I was minding my own business when.......

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post #2 of 10 Old 11-11-2012, 08:04 AM Thread Starter
steveo606
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Location: Lexington
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The first i saw of the jeep, she was on craigslist with no pictures, but it felt like i should hake the hour drive and see it. And the point of no return, pulling the engine and cutting out the old mounts
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post #3 of 10 Old 11-11-2012, 08:08 AM Thread Starter
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So far I've accumulated a list of pieces to the puzzle, most all from the wonderful land of craigslist.
NV4500 from a 94 dodge 2500 with a gas engine. with a 23 spline output shaft
Dana 300
FSJ axles from a J20 (dana 60 rear and dana44 front) with flat top knuckles and 3.73 gears.
4BT came in pieces for a great price
63" 2wd chevy pickup leafs for the rear
and thank God I live 3 miles from Harbor Freight!

The plan is to extend the rear axle, go flat fender, and run HMMWV wheels and tires to keep it narrow enough for some of these Kentucky trails. dual fuel with WVO and still maintain at least 22 MPG.
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post #4 of 10 Old 12-03-2012, 04:49 PM Thread Starter
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These 12 hour days make it tough to get on here and do anything. But Iv'e almost got the frame extension finished. just about ready to weld in.
Iv'e removed the fuel tank, the old rear axle and all the associated hardware. The dana60 is mounted on the chevy springs and under the jeep with no wheels.
but I do still need some parts.
16.5 8 lug wheels.
manual for the nv4500 so i can reassemble it
manual for the dana 44 to reassemble it as well
any help would be huge.
thanks!
Ill post pictures soon. stay tuned!
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post #5 of 10 Old 12-03-2012, 06:30 PM Thread Starter
steveo606
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Out with the old in with the new!
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post #6 of 10 Old 12-03-2012, 07:23 PM
Jason
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Cool build. I'd love to do a 4BT at some point. I'm working on a 360 swap right now.

This might be helpful with your D44: http://www2.dana.com/pdf/5310-3.pdf

Other service manuals are found here: http://www2.dana.com/expertforms/depdf.aspx?prod=AXL


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post #7 of 10 Old 12-21-2012, 07:39 AM Thread Starter
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Quote:
Originally Posted by Jason
Cool build. I'd love to do a 4BT at some point. I'm working on a 360 swap right now.

This might be helpful with your D44: http://www2.dana.com/pdf/5310-3.pdf

Other service manuals are found here: http://www2.dana.com/expertforms/depdf.aspx?prod=AXL
Thanks man! That looks like it will help a lot. Sorry for the delay been super busy,
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post #8 of 10 Old 01-13-2013, 12:21 PM Thread Starter
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its not a dead thread, I've had to postpone jeep things and what not till I get lockers. at least one for the rear.
on the Plus side all the TIG welding I did on the frame extension ive gotten pretty proficient with the DC tig with out the use of a pedal.
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post #9 of 10 Old 02-19-2013, 04:42 PM Thread Starter
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Time for an update, Ive not been on here as much as I'd like but Ive been busy.
When I got the engine it was in pieces Ive completely reassembled it
Now she runs
Picked up some H1 wheels. I want to do the pressed recenter idea, but im not sure how to straighten it up.


So far i have the dana 300 x-fer case mated to the NV4500 with a dodge diesel clutch and bell housing. works perfect so far.



Ive not had to buy any adapters. The trans from the 1994 gas burner 2500 4x4 dodge didnt need anything to mate to the un modified dana 300.

the last pic is what mine will look like when its done...
I still need to source some tires.
I also hit up barns 4wd for a 3 inch drop belly pan, lots of u bolts, and some heims. super fast and cheap shipping
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post #10 of 10 Old 02-25-2013, 07:41 PM Thread Starter
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well i have gotten my hands on a hydro boost, it slides right in woth two news holes drilled. somehow I've got to rig a new break light switch.
research on here has led me to believe that a corvette master cylinder will work. since im running disk front and rear ill need it.
I modified the orgional dodge slave/master clutch assembly, using the tig welder i made the shaft protrude the same amount from the mounting surface as the original did. if youve ever driven a dodge with the 6bt manual trans thats EXACTLY what it feels like. really its quite nice.
using a gm "tractor" alternator its special since its self exciting. and a true one wire that you can pick up for $30 at advance auto parts.
keep in mind most parts guys are going to say they either dont know what your talking about, or we dont have that. trust me, they do.
I used a 8 groove pulley from a 12 valve 6bt and two thick washers, fit like a glove right where is should.
Im getting an accumulator and hydraulic res. this week to help with the steering assist ram i plan on installing.
thankfully Im an aircraft mech so im fairly familiar with how hydraulics work.
In the clutch master cylinder mount i made. i put a square hole in using a hole saw, 1/4" drill bit and some good old fashioned hand files.
It was a booger, but its perfect.
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