Jump to content

Georgia: '92 4.0 Ho, Ax-15, 2Wd


Recommended Posts

I knew I was behind on updates but I didn't realize I was 4 months behind.  Mea culpa :dunno: .  The 12.7:1 ZJ steering box and V8 solid TREs have been in for about 2K miles and there is a noticeable improvement in how she handles. 

 

Georgia ready for the ZJ steering box:

 

Hollow and solid TREs side by side. 

 

Box installed!  Yes the pump didn't need to come out just to reach the box but I was going to replace it.  Long story but the old pump went back in:

 

Note the new TRE at the Pitman arm.  Figured might as well replace it if I had it apart:

Link to comment
Share on other sites

  • Replies 210
  • Created
  • Last Reply

Top Posters In This Topic

Went back over Xmas and mounted the cruise control servo assembly and cable.  Drilling the mounting holes was a pain as I had to wiggle a lot of stuff around to get a straight shot with the drill.

 

 

Cruise is in!

 

Checked communications and everything looks good:

 

 Cruise control works pretty well but is a little "jerky" relative to what I expected.  The junkyard fresh assembly may need to loosen up a bit more or perhaps I need a long, flat run for a true test.  It will hold speed within 2mph but isn't as smooth as I'd expect it to be in doing so.  I've never had an MJ/XJ with cruise so I don't have a basis for comparison.  Can anyone else comment on their cruise control system (either Renix or HO)?

Link to comment
Share on other sites

  • 11 months later...

It's been quite a while since I've updated the build thread.  In late winter/early spring Georgia started having shifting problems that got progressively worse.  She reached the point where I couldn't shift into 1st from neutral when hot so I drove her minimally throughout the year.  I got a quote of $1800 to rebuild the AX-15 so I decided to keep an eye out for a donor I could try to rebuild myself.  I found a suitable candidate at LKQ over Labor Day Weekend:

 

 

Cq1aHn1.jpg

ftqmIYp.jpg

YMbwUCh.jpg

 

WqQ3GHp.jpg

 

 

 

 

 

 

 

Link to comment
Share on other sites

Cleaned it up, ordered the rebuild kit, and cracked it open.  I checked all the clearances, replaced bearings, synchros, shift keys & springs  It was a good donor as the gear train was in pretty good shape.  The 1st gear bearing was starting to go so it wouldn't have lasted too long without some TLC:

 

gHHHlkN.jpg

 

ziawIdC.jpg

 

DWWjbBr.jpg

eUo25ac.jpg

 

 

tfP9kko.jpg

 

5YXd2EQ.jpg

 

jhinhd3.jpg

 

BKgkhYq.jpg

 

ViEubda.jpg

 

nkvXG9d.jpg

 

 

Link to comment
Share on other sites

Pulling the old AX-15.  Flywheel and all the clutch components looked ok:

yuPsTDk.jpg

 

ipLM2Bp.jpg

 

jao0APg.jpg

 

Xd5R53N.jpg

 

0u9j5Rg.jpg

 

Wasn't happy with the LUK plastic throw out bearing at all.  Poor fit and the spring didn't engage the entire front of it:

9Qx2J1s.jpg

 

Ended up reusing the old cast iron unit.  It only had 25K miles on it and was nice and smooth:

YFcSDhZ.jpg

 

 

 

 

Link to comment
Share on other sites

  • 8 months later...
  • 8 months later...

Been a while since I posted an update on Georgia.  New job & moving to TN so I've been working her hard.  She's not a fan of climbing the mountains between NC and TN but she takes it all in stride (55-60mph pulling a long grade in 4th).  Trans is doing well & I should have garage space for her at the new house :banana:

 

 

moving to TN1.JPG

moving to TN2.JPG

moving to TN3.JPG

Link to comment
Share on other sites

  • 6 months later...

Thanks & Merry Christmas!  Work + the move has been all-consuming but yes, I'm happy she has an indoor home now.  She's now sharing garage space with the '69 Cutlass convertible :smile:.

 

Got the pump changed out earlier this week.  Looks like the bearing was going out.  New pump is fairly loud at the moment but I'll drive it for a bit and see if it calms down.

 

 

 

 

ps pump1.jpg

ps pump 2.jpg

Link to comment
Share on other sites

  • 2 weeks later...

The reman pump was junk (sounded like marbles in a coffee grinder), so I hit the LKQ sale and harvested a '94 ZJ P/S pump and another steering box from a '97ZJ.  When I replaced the steering box a few years ago I had to put the old pump back in as I needed her on the road.  Unfortunately the fines from whatever was eating itself in the box/pump eventually ate up the box. Here's what was in the oil:

 

 

steering box 3.jpg

Link to comment
Share on other sites

  • 3 months later...
  • 5 months later...

I can't wait!  I took a lap around the machine shop prior to giving them my engine and was happy with what I saw.  Very clean overall (shop & equipment) and they had a Sunnen SV-10, a Rottler, a VF-3, and a few Clausings.  Interestingly I didn't see a Bridgeport but it was only a quick lap.  He's going to see if he can locate Mahle Motorsport pistons for her.  Good alloy and has a modern ring pack :crossfingers:

 

Link to comment
Share on other sites

Had to change out her steering box again :furious3:.  Last one started leaking at the pitman arm seal and I was getting some scary handling over bumps which may/may not be attributable to the box.  I'll save box #3 for now.  If handling is the same and #4 has issues I can always replace the seal.  So the steering box summary is:

 

#1, OEM.  Started coughing up metal fines.

#2 1st ZJ box.  Developed a dead spot (no assist) when cold.  Had to reuse the pump from box #1 and I'm guessing the fines eventually ate it.

#3. 2nd ZJ box.  Started leaking at the pitman arm seal.  Also some odd handling but we'll see if that's related to box or something else in the front end.

#4.  3rd ZJ box.  :crossfingers:

 

 Also found a coolant leak I need to trace down.

 

 

Steering box Sept 2020.jpg

Steering box Sept 2020 2.jpg

Steering box Sept 2020 3.jpg

Link to comment
Share on other sites

Traced down the coolant leak to the thermostat housing.  Should have been a straightforward project but the top bolt seized to the housing.  Had to cut the housing at the bolt with a Dremel, beat it off the stud with a hammer/chisel, then use some Freeze & Release to work the stud out. 

 

  She fought me on new shocks too.  Upper mount on the passenger's side decided to peel the threads off with the nut.  7/16"-14 die was a decent fit and I had some Top-Lock nuts so I used that.

 

thermostat housing bolt.jpg

thermostat housing.jpg

top lock nut.jpg

upper shock mount.jpg

Link to comment
Share on other sites

After the steering box/shock/thermostat housing battle it was gratifying to take Georgia on a nice road trip.  I put 350 miles on her, she ran great and earned her keep.  I picked up a GN 200-R4 for my Olds and found some other goodies for the fleet.  Perfect junkyard weather: overcast and low 70s in Charlotte.   Also saw a sweet old Vette on I-40.

 

 

junkyard Oct 2020.jpg

c1.jpg

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
 Share


×
×
  • Create New...