Squirrelly Dan: Coheed's 86 Custom

[coheed]

Well, with the 3-4 pack slipping in the 4L60e and it needing a rebuild I had to weigh my options. The cost to build it properly for my hopeful TDI swap in the future is pretty steep, especially when you include a standalone controller if that swap happens.

 

So, when this '90 AX15 and NP231 popped up for dang cheap an hour away I decided to jump on it. Guess I'm gonna need to gather parts to swap the truck back to a manual  . Also, swung by a pull a part local to the guy and managed to score a 2nd shifter, manual pedal assembly, and a spare intermittent wiper box from a 92 2wd XJ for $50.

 

[89 MJ]

How will that work with the bellhousing bolt pattern?

[coheed]

Just now, 89 MJ said:

How will that work with the bellhousing bolt pattern?

The Dakota 2.5 AX15 uses the same 60 degree V6 bellhousing pattern as the 2.5 and 2.8/3.1/3.4. So, Dakota bellhousing, 2.8 externally balanced flywheel and pressure plate, and a clutch disc from an 82 Camaro with a 2.8. With Dakota parts to release the clutch. Not super well documented, but there is a tiny bit of info out there about it.

[coheed]

4L60e is out of the truck. Have installed the new flywheel on the engine and have the AX15 reassembled in the bed.

 

 

Unfortunately the clutch I ordered won't work. The snout for the input shaft splines is too pronounced and hits the crank before the friction surface is touching the flywheel. Instead of getting a shop to cut that down I ordered a Centerforce clutch that in the pictures has a much smaller snout. It should have better friction material than the first one I ordered anyway so why not.

[coheed]

Realized I don't have a fitting to go from the braided clutch line to the quick-connect on the slave cylinder as well. Ordered one from Advance Adapter. Starting a new job on the 1st and would really would like to get this driving again before that. 

 

If rain holds off enough tomorrow I'll swap pedal assemblies and drill holes for the master cylinder, then wait for parts.

[coheed]

Well, yesterday I got the Camaro flywheel, centerforce clutch, and Camaro pressure plate installed. Looking at the Camaro vs S10 flywheel it's no wonder the input didn't touch the clutch. 

 

 

No pictures, but I did get the AX15 and the transfer case bolted in, along with the Novak shifter. Now I have to figure out how to mount the transmission. My truck being an 86 I can't move the crossmember on the frame. So I think I'm going to cut up the crossmember and just weld in a plate and drill holes to accommodate the AX15 stock mount. The output on the t-case is only 1/4" further from the diff, so my new driveshaft should be fine. 

[coheed]

Got the HO style master cylinder mounted with the newer pedal assembly. Along with a new braided steel line to the slave cylinder. The clutch only grabs all the way at the top, so I may get a longer rod made up at some point.

 

 

Cut up the factory crossmember and added some 3/16"x3/8" c channel to move the mount holes back about 2 1/8".

 

 

Had to redo the y pipe again as it hit the AX15 bellhousing. Also wrapped it with some Summit racing volcano wrap to try and keep heat transfer to the cab down some.

 

 

Drove the truck to work the other day. The 3.4 and the AX15 are a great combo. It's been a while since I've ridden in a 4.0 MJ, but it feels comparable to a 4.0 with very minor mods. Unfortunately I think I was sold a bill of goods on the AX15. It grinds going into 3rd, 4th, and 5th. 1st and 2nd seem to have no problem even in motion on a cold morning. I'm going to try re bleeding the clutch, but I'm worried the synchros are toast. Even if I have to rebuild it, I'll still be in it less than what I was planning on spending to rebuild the 4l60e.