howeitsdone Posted August 15, 2022 Author Share Posted August 15, 2022 WJ Power Booster install complete! I will say, nothing mind-blowing lol. You just stop like normal. Pro-tip: Buy bubble flare line from the parts store. My double flare tool is great...for just that lol. Couldn't hack the bubble flare to save my life. Or get WJ lines... I also picked up some composite spacers from Lowes so I wouldn't have to take a lot of the firewall out. Worked great. My only issue with install is the wiring harness that's supposed to go underneath the booster. I forgot to do that... and I damn well don't feel like removing the MC to make it happen. I've cleaned enough brake fluid for awhile. Oh well, the dash brake light isn't really needed anyway. I'll probably leave the reservoir out too since I never use it. Link to comment Share on other sites More sharing options...
howeitsdone Posted August 28, 2022 Author Share Posted August 28, 2022 Trying to track down vibration & rough running issues before the MJ takeover in Moab. I'd like to be able to take it on a trail. Link to comment Share on other sites More sharing options...
howeitsdone Posted August 30, 2022 Author Share Posted August 30, 2022 After a looooong 7-1/2hr drive, a new project is born. I think the AX-4 shifter will have a new home. Just need to get an input shaft for the TC. Bonus points since it's a '96... Link to comment Share on other sites More sharing options...
howeitsdone Posted September 3, 2022 Author Share Posted September 3, 2022 21 spline is out and waiting for the new shaft. Parts start arriving next week! Link to comment Share on other sites More sharing options...
howeitsdone Posted September 20, 2022 Author Share Posted September 20, 2022 This project has become the "I forgot to order that" mecca. So I installed everything over the weekend but forgot the MC and line. MC will be here today, but the line won't until Thursday. Really trying to make the MJ Takeover! Anyway. I swapped the input shaft of the TC and input bearing from BD50-8 to the 6010N 16mm and seems to have fit everything just fine. Had to swap the shifter stick from the AX4 assy to the AX15 base because of the angle. Basically held upright in a vise and torched the base until the rubber melted. Then a pry bar worked with some patience. Jack is under because tapping the new Xmember holes went too easy and I don't trust them yet lol Link to comment Share on other sites More sharing options...
Pete M Posted September 23, 2022 Share Posted September 23, 2022 I've heard so many people say that the dual swap was indeed mind blowing that I'm inclined to think that more tweaking can be done? dunno. I only did the swap once and had to sell that truck before ever getting to drive it. Link to comment Share on other sites More sharing options...
howeitsdone Posted September 24, 2022 Author Share Posted September 24, 2022 10 hours ago, Pete M said: I've heard so many people say that the dual swap was indeed mind blowing that I'm inclined to think that more tweaking can be done? Maybe I'm just practical the truck stops and that's good enough for me lol Link to comment Share on other sites More sharing options...
howeitsdone Posted September 24, 2022 Author Share Posted September 24, 2022 Drove around on the AX-15 for a day and HOLY COW what a crapshoot. So many problems. So, the solution? Rebuild my first transmission! Took a couple of hours but it's disassembled. Ordering parts now and will figure it out next week. Sucks to be missing the MJ takeover, but I'm just not comfortable driving 4 hours with this thing in its current state. Link to comment Share on other sites More sharing options...
howeitsdone Posted September 30, 2022 Author Share Posted September 30, 2022 Whelp. 1st gear thrust washer split itself during install tonight. I think it got turned just slightly and hung up on the pin. Guess I won't be driving this weekend... Link to comment Share on other sites More sharing options...
howeitsdone Posted October 9, 2022 Author Share Posted October 9, 2022 Rebuild is finally done! I have a problem with reverse not engaging fully (still works) and I'm thinking either the detent is wrong or I did the idler gear backwards. I didn't replace the 3rd synchro, but should have because it still grinds a bit. For now I'll drive it and when I'm tired of it I'll fix those issues. I've really missed driving this thing! Link to comment Share on other sites More sharing options...
Pete M Posted October 9, 2022 Share Posted October 9, 2022 a victory with minor complications is still a victory! Enjoy the fruits of your labors! Link to comment Share on other sites More sharing options...
howeitsdone Posted October 25, 2022 Author Share Posted October 25, 2022 Guess I should update. Took it for about a 1k mile trip through the desert last week then stripped her down in a couple hours on Sat morning. Lots of "chores" and finding out where the clunks and rattles are coming from in the front. Apparently I installed the reverse idler backwards and that was the cause of my engagement issue. I had a feeling that was it. Chipped the back of two teeth. I'll run it like this for now since that's the rear side and the contact points will still be good. Also going ahead and using the new 5th gear synchro from the kit and throwing on 3rd to cure the grinding. When I removed 3rd gear, my dumbass let the 3/4 hub hit the ground and crack it. So a new one will be here Friday. Can't be mad if it's my fault Will install a new oil pan gasket as I think something happened when trying to fix the RMS months ago and now it leaks in a couple spots. No biggie. The 231 won't shift into 4lo so I'll pop that open this weekend too and see what's up. Might be the plastic fork slider things. Those were kind of damaged when I swapped the input gear. Bought them but never installed. Also found oil on the top of the bell housing so I'm thinking something is up with the VCG even though I put a rubber Fel-Pro on there last year. I'll inspect once everything is back under the truck and order a new one if needed. It'll be a fun weekend! Link to comment Share on other sites More sharing options...
howeitsdone Posted November 10, 2022 Author Share Posted November 10, 2022 Finally got the new rod bearings installed and new oil pump/screen in there as well. After some royal clenching, she fired up and read ~66psi on the external gauge! Had some loud ticks on the top side of 1 & 2 but seems to have quieted as the engine has warmed. Will monitor this to make sure all is well. Afterwards, I hooked back up the oil pressure sensor and I get no reading, so either the switch or gauge is bad. NAPA will have me one tomorrow and we'll see. I also removed the rear bumper because I was bored waiting for that oil pump. 3 bolts stayed home but the rest came out fine. Was going to order the FEY 6300 but I need a receiver hitch so may wait until after the move to get the JCR DIY kit and be done. Very grateful the motor didn't blow up! Still need to test drive though to confirm, but I'm hopeful. Link to comment Share on other sites More sharing options...
kewper Posted November 11, 2022 Share Posted November 11, 2022 looking good dude! Link to comment Share on other sites More sharing options...
howeitsdone Posted November 11, 2022 Author Share Posted November 11, 2022 Thanks! Link to comment Share on other sites More sharing options...
howeitsdone Posted November 11, 2022 Author Share Posted November 11, 2022 Went to fire up the truck this morning to head to NAPA to pick up my new oil pressure sender and smelled fuel. Sure enough the supply line fitting was leaking at the rail. So after troubleshooting to see if it was the o-rings (that I just replaced) it was in fact leaking at the hose itself. After driving down the industrial part of town I found a hose supplier recommended by NAPA and they threw on a new fitting for me... for FREE I just had to get the old one off. So I carefully took a grinder to the sides and top to keep the hose from being damaged and got it right off. Fuel seems to be staying where it should now! Oh yeah, and the oil pressure sender didn't solve my problem. I'm sourcing a new gauge and I'll trace the wire for now. Link to comment Share on other sites More sharing options...
howeitsdone Posted December 2, 2022 Author Share Posted December 2, 2022 Drove the truck from UT to GA this past weekend. All things considered, it went alright. I discovered the TC leaking in Kansas though and fairly badly. Had to take to some parking lot fixing but couldn't get it to stop. The solution was to "send it" and understand the TC would need a rebuild after. Yesterday I finally was able to get the TC out and I can't actually find where it was leaking. My best guess might be the breather, but fluid was/is everywhere underneath the truck and all over the TC with no visible exit wound. Lots of broken plastic among a couple of other things. Luckily I have the spare 242 and just swapped the input over yesterday. I'll install it today and see how she does. Truck also developed a really bad drivetrain rattle at about 1250-1500 RPM. I think the flywheel might have an issue but that will require more digging and it's supposed to rain here for the next week so that'll be a future project. Link to comment Share on other sites More sharing options...
howeitsdone Posted January 18, 2023 Author Share Posted January 18, 2023 Almost got the rebuild done. See if you can guess how well the head was getting cooled... Link to comment Share on other sites More sharing options...
howeitsdone Posted February 5, 2023 Author Share Posted February 5, 2023 There was a crack in the original head so I had to source another. The one that I found was completely filthy and it took me all day to clean. Got the intake valves lapped and will do the new exhaust valves tomorrow. if all goes well then I'll be able to throw it on the block tomorrow and finally be in the home stretch. Link to comment Share on other sites More sharing options...
howeitsdone Posted April 10, 2023 Author Share Posted April 10, 2023 Small update: Driven 1000 miles as of yesterday on the rebuilt motor and still NO LEAKS! Still check underneath almost every day just in case. I do have a misfire that I haven't tracked down yet because it really hasn't been terrible. Initially swapped out plugs and ran perfect but then came back again so I think something to do with a leaky valve seal because after a cold-start it spits a small amount of oil smoke out of the tail and never does any other time. Plus a little oil on the plug. But I'll figure it out when I'm done with the XJ rebuild. Also welded up a tow hitch and upgraded my 4-pin as a prototype. Still improvements to make on it. Link to comment Share on other sites More sharing options...
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