87Warrior

4.0 flywheels have a curved face unlike the 2.5 and machining will remove it. The FSM recommends cleaning with 180 gritt emery cloth. A Napa (Luk) clutch runs about $10 more than the Duralast. I have never run a Duralast clutch, so I am no help there.

Stu has a pretty good write up here: http://www.stu-offroad.com/axle/d44/d44-1.htm For a TJ, but should be the same for a MJ 44.

She looks pretty clean and nicely built. Good luck getting it on the road. The wait is worth it :)

Do you know how many 99's did roll off the line with the 0331? Will the 99's with the 0331 have a distributor or a coil rail? I looked at several wrecked 99's for my 97+ swap, but never found one with a 0331 head. I have seen reports about it, but never found one in person.

1999 XJs seem to be the most sought after as they are the last year to have the distributor ignition system and a high pinion Dana 30. Edit: They also have the high flow intake manifold.

Been about 2.5 years since my 92 went to the paint shop. Glad I picked up an 86 to drive around!

Pilot was in the flywheel in my '86 2.5. A transmission jack will make the clutch replacement much more enjoyable. Been there, done that with a floor jack and will never do it again now that I have a transmission jack. You should be able to do a clutch swap in a 2.5 with basic tools, no funky external torx to deal with. I would suggest buying a tap/drill bits and new bolts for the crossmember as it will be rusted and the bolts will probably snap.

.....doooo it!

How about a new board, covered in whatever fabric you want with extra fabric for the sun viser. http://comancheclub.com/index.php?/topic/36837-Smsheadliner-Discounts

If the route takes Betty through KS, along I70, I could help tug a trailer across the state. Could you dolly or flat tow it behind the camper behind the CTD?

Those are impressive!

I believe I have a busted 8.25 shaft. I could cut the flange off and mail it to you.

Those vans have always amused me. They are just different enough to catch my attention. It's always nice when a project gets back on the road.

The 2.5 uses these starter bolts: Starter - (2) 3/8-16x4" Listed on page 3 of my '86 build. I used the parts book for a '99 XJ 2.5 to determine the size, went to NAPA and bought the bolts as the hardware store didn't have them.

Where are you located? I have a couple stock steel Jeep wheels. I will let you have one, just make it disappear!

I am disappointed I will be far from a computer tomorrow. Hoping my 3G service will let me do a little streaming on my cell phone while between jobs! Best of luck to all of the drivers!

I am not sure how that could work as the MJ sending unit is side mounted while the XJ sending unit is top mounted? Even if the XJ sender could be mounted, the stock MJ fuel tank is much taller than any XJ tank, therefore the pump wouldn't reach the bottom of the tank. If you have found something that works, feel free to add it to the fuel tank discussion here: http://comancheclub.com/index.php?/topic/30755-dakota-22-gallon-tank-and-fuel-pump

I ordered my LUK clutch kit from www.carolinaclutch.com/ Lightening fast shipping and the best price I could find online. I would suggest buying/barrowing/renting a quality transmission jack. Makes doing a clutch much easier and safer.

The old O2 sensor was a bit, well, missing: The new O2 sensor cured it about 95%. I haven't run a full tank of fuel through it, but it seems my mileage has gone up. General driveability seems to have improved as well. The truck has had a very slight stumble at about 1/2 throttle when stone cold. This goes away after a few minutes. Also, after a hard drive (i.e. into the wind at 70 mph) it will diesel briefly when shut down immediately after.

Neat find. I have never seen one before! Off topic, but I suspect the snow was great in Vail? Is that true? I lived in Vail/worked in Avon for a year. Absolutely loved it!

OP - What is your ultimate goal for your truck? Going with a 60/14 can mean a lot of things. Do you plan on racing, crawling or mud slinging? I believe the stock 2.5 would work well for crawling with the appropriate gears. If you are after a more multi purpose rig, I could see the 2.5 benefiting a lot from boost that kicks in at higher RPM. I haven't the slightest idea if it could handle it or not. Did your 60 and 14 bolt come from the same truck? If so, the front will be wrong (right) side drop and won't work with the 231 you got attached to the AW4.

When that happens.... you are doing it right! Nice find Jim.

Actually with my slow satellite internet connection, it took 12 seconds ;) Poor guy #1. Zero votes. He didn't even vote for himself.

The axle in question is actually a Dana 61, 4.10, limited slip from an 81-83 F350. It is essentially a D60 with thicker tubes, stronger housing and a goofy carrier. I wound up pulling the driver side shaft and bearings this evening. Oh how I hate the smell of old gear oil. I cross referenced the numbers on the bearings and they did not match the numbers the auto parts store said I needed. I ended up ordering Timkens that matched the cross referenced numbers through an online vendor. I wasn't able to get the inner wheel seal number to cross reference anything, so I ordered a set from the parts store and a set from a classic Ford outfit. This is my first time working with a full floating rear axle. Sure is a lot different than the Jeep D30/44! Also considering a Chevy disc brake swap while I am at it.

Does anybody happen to know the part numbers for the wheel bearings and seals for a full floater Dana 60 rear end? I have done some searching and have only found this sold by Yukon Gear: www.ringpinion.com/b2c/ProductDetails.aspx?ProdID=6782&Product=AK_FD60/70&Brand=Yukon_Gear_and_Axle I believe I would need to buy 2 kits to do both sides. I try to buy locally whenever possible, so I would like to find the part numbers, go to the parts store and get what I need. Does anybody happen to know the bearing and seal part numbers? Or will my best bet be pulling the bearings and seals and try to read the number off of them, if at all possible? Thanks!