Vakarian's Comanche 'Trailbreaker'

[Vakarian]

Over the weekend I was finally I finished the overheating repairs. With the removal of the radiator required, I decided at the same time to upgrade to a dual electric fan system since I had a fan sitting around that I pulled off a Comanche in a junkyard.

 

Removal of the mechanical fan was straight forward but took a few fit checks to determine what all had to be removed. Initially, I left the fan pulley on to maintain the same belt pattern. However, the studs for the fan were to long so I cut them as close as possible. Still no luck fitting and now there was no going back. So off came the pulley and removal of the studs leaving a what you see below.

 

Then at work on my lunch break I took measurements of the mechanical fan shroud and superimposed the new electric fan. From there I made a sketch to have a co-worker bend me up a Z bracket to secure the fan. I dug through the scrap metal bin and found two angles that I took and used for securing the lower section of the fan into the slots on the radiator.

 

 

You can make out the three brackets as the fourth holes was aligned to the upper passenger shroud mounting hole. The fan is wired via a fuse jumper into the ignition fuse to start upon start up. Works great but needs an adjustment because when the key is turned off the engine will continue to fun for a few sections before shutting off completely. Remove the fuse jumper and it shuts off normally.

 

Had to buy a new serpentine belt and went with a belt part numbered 840K6. Started the engine to finish the fill up for coolant and the engine was staying at 180 degrees during idle. Upon taking the truck out, it turns out the belt is two long and it slipping. So back to the part store to get a shorter belt.

[Vakarian]

Finally was able to get the Dana 44 re-geared by a local fellow I was recommended. The previous owner had started to do some work on it and took the brake drums to the dump, so I decided to covert the axle to rear disk brakes. I bought a kit online since the local junkyards were charging a large penny for the parts and for a little more could get new parts.

 

 

Don't mind the messy garage, in the works of organizing, but my girlfriend got me differential covers as a gift. I saw a discussion and links on here regarding different covers for axles and I left the tab open.

 

 

Well the kit for the disk brake conversion aligned and bolted up, but allowed a 1/4" of movement for the axle. So will be making a spacer at work via the water jet to take movement out. Additionally, I had to open up the center of the rotor allow it to sit properly on the axle shaft. One the spacer gets cut out , the axle will be completed and ready for install.

[Vakarian]

Well truck has been down and set on front jack stands. Pulled in the driveway after work and more coolant poured out onto the ground. So out of frustration, I lift the front end and pulled the front axle out.

 

 

Turns out after getting the axle out I noticed a lot replacing need to take place. So with that new bearing hubs and bolts, ball joints and upper control arm mounts were ordered because they were royally shot on the axle. Also planning on getting new calipers and rotors as the passenger side seemed ot have locked up on the rotor making a nice plateau.

 

While waiting on the axle to get reared geared, I returned to finishing up the transmission. All the internals all back together waiting for the housing to go back on. The following pictures are before I completed putting the detente balls and springs back in.

 

Otherwise I have been working on setting up a new relay box to handle the new lights within the bumper as well as later upgrades since currently the fog light wiring is tired down but is so unclean. I have been enjoying them till the axle got yanked out. First picture below is as I drive down my driving heading to work, while the second is on the main road.

 

 

Well that is all for now while I continue to figure out why my truck keeps loosing coolant and work to replace the heater core and evaporator in my finance's Cherokee. Otherwise, have a great day everyone.

[Vakarian]

Hello everyone! I apologize for the all the info piled into this post.

 

Been busy and forgot to update the progress of the truck. The truck got front axle reinstalled and moved into the garage for the work on the rear axle swap. Not focusing and remembering I forgot to take pictures of the process on the swap.

 

DANA 44 Rear Axle

 

So in the process of swapping in the new DANA 44, I replaced and upgrade the U-bolts. I ordered 5/8" diameter x 2-3/4" inside width x 7-7/8" long replacements from Plattsburgh Spring Inc [UBoltsDirect.com]. The bolts were larger then OEM and required a bit of grinding to open the spring plate holes some.

 

 

 

For the new brake lines I went to NAPA and ordered new front brake caliper rubber lines for a Comanche/Cherokee to use in the rear calipers. All I had to modify to get the lines to work was cut off the joggle tab where the hard line connected for the driver side. For the passenger side the joggle tab gave a nice mounting hole to secure the connection. 

 

 

From there I learned that I am terrible at bending hard brake line but overall it worked out nicely.

 

 

With the rear axle all that is left is to run the breather line up to the engine bay as a manifold is in the works for all the breathers. The manifold is a project for me to learn the end mill at work. As the brake lines were affected, I took the opportunity to replace/upgrade to a dual diaphragm brake booster. Booster is current now in temporary in place so I can work on determining the required brake line bend and lengths required in case the booster needs to be removed.

 

 

Additionally, the area in front of the A/C fan was open and built a bracket to hold a relay box and additional pre-wired relay holders that attaches under the hood bar to hold it open.

 

 

So with that you all are caught back up on the process of where the truck sits. Please let me know of your thoughts or feedback on the anything you see to help me improve the work being done. Thank you and have a wonder day / evening.

 

[Pete M]

lookin' good!   which rear brake kit did you go with?

[Vakarian]

Thank you Pete M!

 

I did not order a kit as I wanted to ensure the rotors were the same for all four wheels. I just bought the backing / parking brake plate separate forgetting the tapered spacer at first. Then just order new calipers and rotors from the local auto part store. Still working on the parking brake portion but still trying to determine how to replace the release handle as the cable snapped there. 

[Vakarian]

So before assisting my buddy CapitalCityPioneer with obtaining his first Comanche, I had been fighting with some front coil spring issues. The passenger coil spring was aggressively rubbing  with the sway bar connect due to some bowing.

 

[passenger of left & driver on right]

 

This had been fighting me for a few days and got me frustrated due to only one side having the issue. Thankfully I had my new shop buddy hanging out with me who enjoyed being "helpful". He doesn't understand the concept of staying clean.

 

I ended up having to disconnect everything like 3 or 4 time and had to re-adjust the control arms to re-position the  axle placement. Additionally, found out my sway bar disconnects were too short and was adding to the problem. So after getting that fixed and taken care of, took the truck for a short test drive to the post office down the street to check my mail. Returning home and shifting into reverse with my wheels turned, white smoke began rolling into the cabin. Turns out my high pressure power steering hose had blown and would squirt fluid on the exhaust when wheels were at full lock.

 

 

Now waiting on a new line to come in as well as preparing to drain the front diff to tap the breather hole as my insert failed to stay in. Now work will focus on finishing the 5-speed transmission as the truck currently has a top speed of 65 mph @ 3100 rpm with the current AX4 and 4.52 gears on 32" tires.

 

[Pete M]

that is weird that only one side was bowing, but glad you were able to sort it out.  

 

also, helper dogs are the best    when I get another dog I'm going to teach her how to fetch the 10mm wrench. 

[Vakarian]

Thanks Pete M! It had me stumped by the single side only bowing as everything was measuring up relatively equal. And yes, helper dogs are the best indeed! Getting the 10mm wrench is a an amazing idea because that size is always need when you can't find the wrench 

 

Additionally, while waiting on parts for the power steering to arrive, I have been working on a how I want to move the air intake higher up. Not sure if I want to go the cold air intake route, just want to move intake away from behind the light.

[Vakarian]

Oh so CapitalCityPioneer found a factory roll bar for his SWB locally after posting in the areas jeep group. Not wanting to keep it in the back of his Honda Integra and to get it out of the way, we stuck in the back of my MJ as his bed is full of parts. My fiance walked out into the garage and instantly replied how she liked how it looked and said not to give it back. The lucky man got the factory frame brackets with the roll bar as well. His build thread is below but I am still working on reminding him to take pictures as he works. 

 

 

https://comancheclub.com/topic/58824-1988-comanche-barn-find-project-for-a-new-jeeper/

[Vakarian]

Been an exciting few weeks here.

First the track bar nut sheared off on me causing me to slide into a minor ditch. Found some rope in the truck and tired it back up to proceed the 10 miles home at 35 MPH. Steering was terrible and honestly amazed that it actually worked. Got half down my driveway before the rope broke. Had a second piece to finish the trip.

 

About a week later the following happened causing the Comanche to be sitting in the driveway again.

 

A stud sheared off from the driver side bearing hub causing the tire to fall loose.  Lucky i caught it and was able to make it to the shoulder before it completely fell off Jacked it back up after running the few miles back home for tools. Gauged the heck out of the rim so it will become the spare rim after i order a new one. Just had to wait for the new bearing hub assemblies to show up 

 

Now this past Saturday, after the the hubs arrives on Friday, the 4.2L in my 88 wrangler decided to blow the head gasket and throw a rod through the oil pan about an hour fifteen from home. Took about four hours for AAA to get me home.

 

 

So with all this happening, the wrangler is getting stripped of parts to allow the rebuilt transmission I have been working on to be installed in the Comanche. Sunday involved removal of the wrangler transfer case with the transmission following. Going to be taking the bell housing, clutch parts including the master cylinder and clutch plate, and transfer case from the wrangler and put into the Comanche to get the five speed in there.

 

Trying to decide if I should and worth it to rebuild the transfer case before installing.

[CapitalCityPioneer]

Had some quick little fun with Vakarian and Trailbreaker this past Friday. Decided to take the hill instead of the road down and up lol!

 

But, a quick little flex action shot....! Enjoy.

 

 

 

[Vakarian]

14 hours ago, CapitalCityPioneer said:

Had some quick little fun with Vakarian and Trailbreaker this past Friday. Decided to take the hill instead of the road down and up lol!

 

But, a quick little flex action shot....! Enjoy.

 

Thank you for getting those shoots. Wasn't a big hill but fun never the less.

[CapitalCityPioneer]

Thanks Vakarian! Can't pass up showing this beautiful photo of your baby putting in work

[Vakarian]

1 hour ago, CapitalCityPioneer said:

Thanks Vakarian! Can't pass up showing this beautiful photo of your baby putting in work

 

 

Anytime man! ComancheClub members stick together and help each other out!

 

 

So my red Comanche was running a bit warm the entire trip but never got to the point of over heating. We stop because we were hearing a loud grinding noise coming from somewhere. Upon stopping the temp gauge started to creep up so I popped the hood to make sure nothing was wrong and I had fluid.

 

Turns out a gasket around either the thermostat or water pump decided to start leaking again.  But from there on out I just make sure there was extra fluid in the tank and only reached 230 when we entered the city and we'er stuck with standard city slow driving. Under normal driving condition it was warm a bit but started at 215.

 

All and all it was a fun little trip.

[Pete M]

mini PowWows are the best   

[Vakarian]

Pete M, they are indeed the best and not back to work in the garage.

 

Here are some pictures from my trip in paradise. It was a nice trip but now its time to catch back up on the projects and remember how to be productive at work.

Been working on getting the junkyard gem back up and run only to have Trailbreaker blow out its clutch slave cylinder on me as well now. So once the Junkyard Gem Comanche is completed time to swap out the AX4 for an AX-15 transmission. Only have a weekend and a half before I need to drive to North Carolina for a paintball event so no time to waste.

[Vakarian]

►.......... WRENCHING STATUS TRANSMISSION INCOMING ....................◄

 

Alright got the Trailbreaker into the garage and started wrenching to swap in the rebuilt AX-15 with modified counter shaft. Additionally, the final parts for the transmission arrived to finish the external slave cylinder swap and new shift cover.

 

 

Had a nice scavenger hunt to find enough blocks to reach and support the transmission and transfer case during skid plate removal.

 

Removed the long arm bolts to the skid plate first followed by the transmission attachment bolts while a motor cycle jack head up the skid plate so I didn't strain or crush myself.

Now with the skid plate, out time to start disconnecting electrical lines and draining the fluids so it doesn't leak every where again this time. 

 

Also did a sight inspection for future lights to be mounted on top of the truck once my supply rack gets completed in the future.

 

 

That is all for now till more work gets completed tonight after work. Have a great day everyone!

[CapitalCityPioneer]

Hopefully this one comes apart more easily than the Junkyard Gem!

[fiatslug87]

Wow, that's a shiny shifter, is that how they're all supposed to look? 

[Vakarian]

10 hours ago, fiatslug87 said:

Wow, that's a shiny shifter, is that how they're all supposed to look? 

Apparently, it blinded and confused me when I first opened it. Now the real question is how look with the shiny last?

 

►.......... WRENCH STATUS TRANSMISSION INCOMING .......................◄

 

Today should be the day to find out how easy the transmission is going to come out. The 4x4 shifter and clutch line are the two remaining items left to remove before transmission process begins. 

 

The afternoon wrenching was delayed due to errands and helping the wife. But once in the garage the transmission mount, rear drive shaft, and exhaust came out smooth with little to no problems. Only problem was the bolts for my custom exhaust mount behind the muffler has some unnecessary long bolts that were annoying to remove the nuts from. (Will get a picture to show the bracket picking up the double hanger mount)

 

 

From there had a little oh  and  moment. I was not paying much attention to the whole system when I started to remove the front drive shaft. The long arm front suspension connects to the skid plate so forgetting to reduce the pressure on the coil springs I began remove of front drive shaft. Well once the tension was loosen, the front u-joint slide out of the yoke and the front axle began to rotate forward to release the pressure stored in the springs. 

 

So my wrenching buddy (CapitalCityPinoneer) had to hustle to get blocks, boards, and a jack stand piled up to support the front bumper to keep the truck frame from falling while I'm using the long arm to keep the axle from rotating more. After some hustling and scavenger hunting, we got some saw horses and board to a height the remove 90% of the compression force within the springs. 

 

 

From there the front drive shaft was removed from the transfer case and stored with the rest of the parts. New u-joints are on order to replace the worn front drive shaft units.

 

 

Other than that, the front bearing retainer for the transmission was sealed up and secured to the transmission and the new breather value is getting tapped today at work. Pictures for that will be shown in the next update.

 

► .......... WRENCHING STATUS COMPLETED .................... ◄

[CapitalCityPioneer]

On 10/24/2019 at 7:09 PM, fiatslug87 said:

Wow, that's a shiny shifter, is that how they're all supposed to look? 

That's exactly what I said

[Vakarian]

►............ WRENCHING STATUS .....................◄

 

With the dead line approaching for the trip this weekend, I am still fighting with the last bolt to release on the transmission. So with resisting my initial frustration of just using the logic of "Can't be stuck if liquid" by cutting the bell housing, I got myself a die grinder and have been trying to grind the bolt head down to allow removal.

 

However, my portable compressor is not suited for the continuous task of running the tool so I have to wait for the tank to refill. Therefore, in that time I finished up the work on the AX-15 transmission that will be going back into the truck.

 

The version of the transmission has an internal breathing vent which I didn't want to use as he has to vent through the shifter cover so I instead tapped it for a 1/8" NPT hose barb for a 3/8" hose. I forgot to take a completed picture before installing on the transmission. 

 

       

 

From there I wanted to double check the transfer case I had was going to mate up. Everything aligned and the transmission was having no issue shifting. With the time deadline I didn't try to clean the transfer case any, don't get made.

 

 

From there some new headlights came in to replace the factory lights that finally died on me. Only the driver side went out on me but the they were terrible in my truck to the point where my wife would consistently ask if my lights were even on. Before anyone ask, no I have not installed the relay system yet but that is my first thing to do after this weekend. Been working on my wiring diagram to ensure everything is right and that I have time to not rush before tearing into that. But here is the new headlight installed.

 

 

I enjoy the old factory look so I just ordered some cubie replacements with 60/55w H4 bulbs from Daniel Stern Lighting. Shall see how they work before the relay install and compare afterwards. From there that is what has occured last night, in between spending more of the time with terrible grinding wheel eating away at the one bolt holding the entire swap up. 

 

Here is to hoping that today allows the transmission to be removed and swapped. Util next time.

 

► .......... WRENCHING STATUS COMPLETED .................... ◄

[Vakarian]

►............ WRENCHING STATUS .....................◄

 

Well it was a long night but the four speed AX-4 has been removed!!! Used a ratchet trap to help with the disconnection pull then man handled around on the motorcycle jack to slide it out from under the jack!

 

 

 

Cannibalized a few parts off it [reverse light sensor and intermediate shift handle] for the AX-15 re-install. Had to make a quick modification to the bellhousing for the crank sensor as it came off my 88 Wrangler that has a carburetor . Started to just cut out a section for the sensor to fit through but was getting issues with the attachment bolts alignment, so after cutting the whole out for it, I just rip the plate off.

 

 

The AX-15 and NP231 all bolted together and filled up ready to be installed. External slave cylinder was also cannibalized from the wrangler as well and installed into the engine bay.

 

 

Tomorrow should contain pictures of the transmission back into the truck. Until next time have a great day / night everyone.

[Pete M]

if you get a free moment, could I get a part number off that AX-4?