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Discussion Starter · #1 ·
97 tj 5.9 unlimited rebuild,

Well I thought I would start a Build thread, Well if you want to call it that. I Bought a built project/ wiring Nightmare. But be for I get in to the new project, I thought I would ramble on about my old jeeps...:D I'll start with my first love. It was a 79 cj7 that had more bondo then metal lol Bondo everywhere:eek: not that it needed it It did not have a lot of rust or anything. ever body line crack and place where a body panel met another it will filled with bonbo:mad: but enough talk about bondo and talking for that matter. I like pics!

The day I brought her home



The first time I took her out to play




started rebuilding her...










the day I sold it:(



Now moving on to my other old 97 tj less pics I was building a track car when I started on the old tj







The day I sold it:(

 

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Discussion Starter · #2 ·
Well now where finally At my current Bought built mess

Its a 97 tj that has been stretched to lj specs 3 link front and rear dana 44 up front dana 60 in the rear 4.56 gears 5.9 magnum swap with the 46re trans and stock np231 and a hack job of a wiring harness.

The day it came home.












started collecting parts out of the junk yard one door two smashed up fenders






The wring harness:mad:














 

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Discussion Starter · #4 ·
I tried to start it for the first time in over a month and its not getting spark. I can hear the fuel pump running. I may have pulled a wire loose in the harness as a few other things are not working. The voltage gauge is not coming on when the key is on the gas gauge is also not coming on it should be sitting at a little over half a tank and the tack is not moving when I try to turn it over:confused: So it looks like I will be pulling the harness tomorrow:(





 

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Discussion Starter · #7 ·
Good looking rig , loved the old grille but they are hard to make fit . And your a better man than I am digging into that rats nest of wires ...
Thanks!, I do love the old grill it makes great wall art that said if it was a GPW Grille I would have made it fit. The wiring was a mess but other then the speedo everything works great.
 

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Discussion Starter · #8 ·
It over heated over the weekend got up to 220 ish. I also bent the fender.





Today I fixed the overheating problem. I don't have a heater on the jeep yet and I have the line looped and it was getting air in it as it was sitting higher then the rest of the system, now it stays at 200*. I also fixed the fender and took a few more poser pics. I need to remember to remove the front sway bar.





 

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Discussion Starter · #9 ·
This happened the other day:eek:




The trans cooler hose busted, I did not see it till I got back from washing the jeep out back.

Since there wasn't much trans fluid I thought I would drop the pan to see why I would not shift.







Found it, Oh look its my drive band!:(








Today I bought some more atf4 filled it up. I plan on doing a 5 speed swap on it down the road. The way I see it Ill wheel it till I cant.
 

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Discussion Starter · #12 ·
Hey thats a really sweet 97 tj you had! could you tell me what kind of lift and tires were on it? and whered you get that sweet pioneer logo? thanks for your time!
-Nick
Thanks!, It had the rubicon express 6.5 long arm lift, I was running TSL 35x14.50x16 the logo was a nos pioneer edition comanche decal set that I had.
 

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looks fantastic, thank you so much for removing that willys grill. nothing against them but that did not belong on that jeep. looks 10000x better now
 

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Discussion Starter · #15 ·
Subscribed. Post info on the 5 speed swap.
I will try to post up as much info as I go.

looks fantastic, thank you so much for removing that willys grill. nothing against them but that did not belong on that jeep. looks 10000x better now
HaHa yea, It does look a lot better, however if it was a GPW grill I would have made it work. The 48 3b grill was just to tall.

I finely have most of my parts for the 5 speed swap. I went with the NV3500 trans out of a 02 dakota. This puts the shiftier a few more inches back from the 94-98? nv3500. I went with the summit racing flywheel and a autozone replacement clutch for the 5.9 magnum. I am experimenting with using a master and slave cylinder out of a 85 wagoneer as I don't like the plastic crap and it 1/3 of the price. Im also going to have to move the motor mounts a little over 2 inches back as the nv3500 out of the 02 dakota is a little over 2 inches shorter then the 46re. That said the 94+ nv3500 is about the same as the 46re. I will have to do some cutting and fitting of the firewall.

The NV3500






The new flywheel



New clutch



The new master cylinder, you can see I had to drill new holes but the linkage fits




Started to pull everything apart.







Engine and trans out!








Test fitting the flywheel



A few more shots of the slave and how I modded it. I still ned to make something like a spacer to keep it from moving.



 

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Discussion Starter · #16 ·
Cut out the motor mounts and moved them back two inches.



Driver side firewall clearance I'm going to have to go with a different set of headers.



Pass side has plenty of room.



trans clearance.





I had to re do the trans mounts and they are wider.







modded motor mount.



modded trans mount I may end up running a sleeve through the tube for the other mount.





Mounts welded in.





Had to put a few washer in for the auto crankshaft position sensor.





Installed the clutch.




modded the wagoneer slave more





Engine and trans are back in!


 

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Discussion Starter · #17 ·
Went to a swap meet this week end traded some junk for some more junk:D

Traded a drive tj half door for a set of yj full doors, they need a lot of work,






traded a cj7 tailgate for a cj7 dash that I may try to use.




 

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Discussion Starter · #18 ·
Started work on the doors. I started with the passenger as it has less rust.

I took some one inch and half inch square tubing to replace the window channel.

mocking things up.





I cut the one inch tubing to be the same size as the inner window channel and primed it as there will not be much room to paint it when its in.






I then took the half inch tubing and started work in the outer seal channel.




I then took the outer one inch tubing that I cut off to make the inner channel and finished the outer seal.





I then welded everything up and smoothed out the welds and primed it. It will still need filler to clean ever thing up.






 

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Discussion Starter · #20 ·
Well I painted the headers and brake master cylinder.



I made a trans cover.



I may or may not use this boot that I bought a few years ago for a project.



I made block off plates for the fire wall





I made a cheap exhaust that will work for now.




where I stopped to night

 
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