Limeyjeeper

That probably wasn't helping your lack of vacuum if it was leaking.

The last 6 of the VIN are also stamped on the frame. I just can't remember where. I think by the front lower control arm mount.

Crazy fab skills. I can only dream!!

52006221

If you have time feel free to stop by, you would be most welcome!1

I also took her out for a proper test drive tonight. This sucker is fast........................

Just a beautiful truck. Keep up the good work. These gems need to be preserved. Kudos to you.

So to get all the stock gauges working on a 91 Jeep LS Conversion using an NP231 or NP242 transfer case you need to do the following:- Speedometer - Simply connect the stock VSS signal, Pin to the White/Orange G7 wire going into the instrument cluster plug. The diagram below is looking from the back of the plug. How do I know. I thought it was the front and wired the plug wrong initially. You will also need to tap this wire into the Dakota Digital box (see below) Coolant Temperature You need to use GM Part no 12551708. This is a 3 pin sensor. Pin C is the pin you use to drive the Jeep Coolant temperature gauge. Pin A and B go to the LS PCM as it needs to be able to read Engine Coolant Temp. Pin A is Low ref, Pin B Sensor Signal. Connect pin C to the Violet/Yellow G20 wire going into the instrument cluster plug. Volt Meter - Nothing needed it reads the voltage from the instrument cluster fused ignition feed White/Black A9 Oil Pressure You can use the stock Jeep oil pressure sensor 56026782 with an adapter. I used a earls AT9919AUJERL adapter so it will fit the oil hole at the rear of the block. It is a M16 x 1.5 to 1/8 NPT. Available on Amazon. Tachometer - Surprisingly All I did was connect the LS PCM Tach output (Pin 10 on the RED Connector) to the Gray/Black A6 wire going into the instrument cluster plug. Works perfectly Fuel Gauge. I used the stock fuel sender unit and a stock Jeep Fuel pump. No issues. The final piece of the puzzle is telling the GM PCM what speed the vehicle is going. This is used for Cruise Control a couple of other things. As I mentioned earlier in this thread I used the Dakota Digital SGI-100BT. It has a bluetooth interface which makes programming very easy. You set Speed (SPD) to App 2 which is L-L (low speed signal in, low speed signal out. You connect the output from the Jeep VSS Orange/Tan to Input on the DD box and OUT 1 goes to Pin 21 VSS High Signal on the Red Connector of the LS PCM. The DD box converts the Jeep VSS Square wave output to the LS PCM required AC Sine wave input. Sorry for all the painful detail but it might help somebody doing an LS swap do a little less head scratching!!

Another milestone. All the factory gauges are working. Just got to play with the Dakota Digital box to get the LS PCM to see the speed.

This Digital Guard Dawg keyless ignition kit is awesome. They aren't cheap but the Resto community swears by them for reliability. To install in a 91 harness you need to connect the following wires Both RED to Red on the DD Yellow to Purple Orange to Pink/BK Violet to Brown Dark Blue to Pink Ground the Black White/Tan Brake Light cold side to Brown on the DD Accessory Harness Dark Clue/Red Parking light feed out of the light switch to Gray on the DD Accessory Harness (Flashes park lights when arming and disarming As I have central locking. I used the Autoloc system I also wired the following Brown Unlock to White White Lock to Green Walk upto the vehicle automatically disengages the ignition shutdown press the key fob to open the doors. (Or you can manually set it using the key fob) Get in. Foot on the brake and press the start button. Simple as that. Lot of power going through these wires they need to be done right Double Sleeved Once it is all wrapped and in loom you won't see the labels. Don't want to make it too easy for the bad guys!!

I am going to wind in my adjustable slave a bit and see if that works. I am also concerned that the distance between perfect and eating the thrust bearing isn't much!! I am ready for a Tremec 5 speed too!! It would be an awesome conversion. Can handle a ton of power. Nice ratios too 1st 2.87; 2nd 1.90; 3rd 1.34; 4th 1.00; 5th 0.68. Vs the AX15 at 3.83, 2.33, 1.44, 1.00, 0.79

Is your new slave holding up? What did you replace the throw out bearing with?. I am just about to pull my Trans. My clutch is now at the top of the travel and slipping. Not good. Hopefully as I have the Jeep bellhousing it will be easier. Going with Jeep throw out bearing and Jeep fork. We will see how that plays out. Novak really should have better suggestions on the clutch setup. Pretty annoying. Their setup instructions for their adjustable throw out are laughable. Hopefully soon we will be able to tell the world the right way to do this!!

Keyless ignition being installed. The kit is really excellent. I gutted the steering column interlock, key barrel and mechanism that pulls the ignition switch rod. Replaced the ignition switch with the push button. Fitted perfectly. Works with central locking so I only need one keyfob.

Running pretty well now!! Engine running.mp4

The HO PCM can dial back the injector pulse rate pretty well. I run Ford Motorsport 24lb Cobra injectors (Blue body) in my Stroker and they work fine. The Bosch injectors work well too. I have used https://www.fiveomotorsport.com many times over the years. They have a great quality product.

You really need 21lb injectors. The Mustang injectors are 24lb. They are 4 hole. Here is some info on injectors courtesy of Dino Savva. Injectors Some of those specs that are hard to find in any workshop manual. The following is a list of the injectors used on the 4.0L since 1987 along with their rated static flow: Model Year, ...Part #, ...........Colour, .....Fuel Pressure, ...Static Flow, '87-'90, ........53003956, .........Dark Tan,.......39psi, .................21.0lb/hr '91-'93, ........33007127, .........Brown, ..........39psi, .................21.0lb/hr '94-'95, ........53030343, .........Tan, ..............39psi, .................21.0lb/hr '96-'98, ........53030778, .........Grey, ............49psi, .................23.2lb/hr '99-'04, ........04854181, .........Blue tip, ........49psi, .................22.5lb/hr '05-'06, ........53013690AA, ....Brown tip, .....58psi, .................25.4lb/hr The injector flow rate varies as the square root of the pressure drop across the injector. The stock '91-'95 4.0 injectors are rated at 22lb/hr @ 43psi fuel pressure, so at 39psi they flow ( sq. rt.(39/43) x 22.0 = 21.0 ). For stock/modified 4.0 engines or stroker build-ups the following injectors can be installed. The flow rates are: Ford Motorsport 19.0lb/hr @ 39psi (Part no. FMS-M9593-C302) Ford Motorsport 24.0lb/hr @ 39psi (Part no. FMS-M9593-A302) Ford Motorsport 30.0lb/hr @ 39psi (Part no. FMS-M9593-B302) Bosch 0280155712 19.4lb/hr @ 43.5psi Bosch 0280155703 22.7lb/hr @ 43.5psi Bosch 0280155715 23.7lb/hr @ 43.5psi Bosch 0280155849 24.5lb/hr @ 43.5psi (same as Ford XF1E-A5B) Bosch 0280155784 26.3lb/hr @ 43.5psi Chevy LT1 24.0lb/hr @ 43.5psi (Part no. 17124248) Chevy LT4 28.0lb/hr @ 43.5psi (Part no. 17124251) '98 Chevy LS1 25.2lb/hr @ 58.0psi (Part no. 12533952) '99-'00 Chevy LS1 26.2lb/hr @ 58.0psi (Part no. 12456154) '01-'02 Chevy LS1/LS6 28.6lb/hr @ 58.0psi (Part no. 12482704) Accel 19.2lb/hr @ 44.1psi (ACC-150119) Accel 21.1lb/hr @ 44.1psi (ACC-150121) Accel 24.4lb/hr @ 44.1psi (ACC-150124) Accel 25.6lb/hr @ 44.1psi (ACC-150126) Accel 29.4lb/hr @ 44.1psi (ACC-150130) The '95 Jeep 5.2 ZJ/Dodge 5.9 injectors (Part no. 53030262) are rated to flow 24.6lb/hr at 39psi. The selection of injector size will depend on the estimated horsepower output, brake specific fuel consumption BSFC (assume 0.5), no. of cylinders, and the injector duty cycle (assume 80% or 0.8). The formula is: Injector size (lb/hr) = (horsepower x 0.5)/(no.of cylinders x 0.8)

Very cool build!!

Got HP Tuners working, now playing with the tune a bit. Getting ready to take her for a spin. Going to delete the heater valve it is really in the way. Got the steering aligned "redneck style" 2 bars, some bungees and a tape measure. Next up heater core leak, then I need to pull the NOS leaking NP242 transfer case. Slowly getting there. Going to take her for a safety next week. In Texas you don't need a windshield to pass a safety inspection so long as you drive there wearing goggles. Go figure. I really need to put some miles on her to get the PCM to start learning.

What year is your Comanche?

Second on PPG great paint. Used it on my build

Yes they even couldn't be bothered to use different colored wires for each side!!

So after a frustrating time trying to track down the LS engine issue (misfiring, popping, down some cylinders) I finally cracked the problem. It is possible with a GM LS engine to put the coil pack harnesses on the wrong way around. This causes the driver side bank to not fire on two cylinders. Rookie mistake by me. So for the next guy:- Drivers Side #1 Cylinder Purple wire #3 Cylinder Light Blue #5 Cylinder Dark green #7 Cylinder Red Passenger Side #2 Cylinder Red #4 Cylinder Dark Green #6 Cylinder Light Blue #8 Cylinder Purple Purring like a cat now....

It's cool and trust me my patience has been worn extremely thin on many occasions with this build!! Still fighting non firing on a couple of cylinders, pretty sure it is a bad PCM. Putting a replacement in tomorrow.

I got them from Core4x4.com

Catalytic Converter Laws in Texas BY HERB KIRCHHOFF The catalytic converter in motor vehicles is an anti-pollution device that chemically converts toxic byproducts of fuel combustion into gases that occur naturally. Some drivers believe that removing the converter will improve performance while others may seek to replace the converter with a section of ordinary exhaust pipe to avoid the cost of replacing a failed converter. Such actions are against Texas state law, and violators face up to a $25,000 fine. Tampering Illegal It is illegal in Texas to tamper with properly functioning catalytic converters and other pollution control equipment, says the Texas Commission on Environmental Quality website. Tampering means removing, disabling or otherwise rendering inoperable the pollution control devices installed on a motor vehicle. Use or Sale Banned Texas law forbids you to drive a motor vehicle with missing or inoperable pollution control systems. This applies regardless of whether the vehicle is being driven on- or off-road. It is also illegal in Texas to sell, lease or offer a motor vehicle that doesn't have all pollution control systems in proper working order. Repair Rules Chapter 114 of the Texas Clean Air Act requires that a missing or failed catalytic converter or other failed pollution control device must be replaced with one specified for that vehicle and which has been certified by the federal Environmental Protection Agency. The repairs must meet the emissions standards established for that vehicle. It is also illegal to add equipment, such as a turbocharger, that wasn't originally certified by the manufacturer for that make and model. Exemptions Texas law exempts vehicles and engines used exclusively for auto racing, research and development, or vocational instruction. It also exempts farm vehicles made before 2000, and vehicles or engines being exported from the United States.