DZ’s ‘87 SWB TDI Swap

[Diesel_Zuk]

Just joined up here, I’ll have to spend some time learning the site, but wanted to start my build thread here too. 
 

Formerly I was (and still am) a Samurai fanatic, and had TDI swapped my first one, which I owned for almost 10 years, and recently sold. 
 

I’ve always wanted a Comanche, and was browsing the local classifieds when I stumbled across a shell for $400. I offered him $300, and I believe I ended up paying $325. 
 

‘87, SWB, no bed (came with a BEAT long box, just the box, not a whole truck) no engine, trans, front axle. 
 

I had a 6.0 and 4l80e I thought about dropping in, but looking at pix, it looked too tight for my liking. So I decided to TDI swap it. Hoping for a 99-03 ALH, but all my leads keep running up dry, so I may settle for a BEW or BRM if I can land one of those. 
 

[Diesel_Zuk]

First order of business, find an axle. I settled on a free dana 30 from a ‘96…..the catch was I HAD to take the 35 away as well. Which works for me, because I wanted an 8.8, and needed a core to turn in. 
 

Picked up this 8.8, 4.10 LSD for $166 after fees and dropping off the core. 
 

 

Goals with build is how I liked my Samurais, mild, with maximum streetability since I drive a lot. So I am planning on staying SUA. Picked up a Deaver kit from RuffStuff to do this nice and clean.

 

[Diesel_Zuk]

Picked up two sets of coils, 4.5” Rubicon Express and 3” Rusty’s to figure out what I want. Got a used set of short arms. And some free wheels and tires to roll it around on. 
Yes the arms need adjusted bad, in the pic the axle was literally just hanging. It’ll get there! Eventually, 

 

 

 

Also picked up a used 1 ton steering setup to throw under so I can get rid of the stock steering setup. 

[Diesel_Zuk]

For tires, I wanted 31’s-33’s max. I’m a big fan of cheap tires, and have scored 255/75r17 jeep take offs cheap multiple times, including this time. Although I’m not 100% sure they’re jeep takeoffs, I suspect they are since the new JL’s have a Destination MT2 option.

 

Gave $450 for the set of these brand new 255/75r17 MT2’s, which equates to around a 32x10.
And I love pizza cutters!! I know they’re not for everybody, but after wheeling in Moab, and since I live 3 hours away and plan to wheel there with this truck, I wanted to stick with skinnies. 
 

Picked up a set of JK 17” wheels to fit the tires on. Got 1.5” adapters for the front, and 2” for the rear to help match track width of the 8.8 to the D30.

[Diesel_Zuk]

Needed a transmission, and looked hopelessly for an AX15 until one day I happened to stumble across one! Seller claimed it came from an ‘87 Manche, but the NP231 was a late style. Bell housing is internal slave, so it must be a mutt if stuff. Oh well, scored it fairly cheap with the tcase in comparison to what most people want for trans only. Only problem, missing the shifter and tower. I bought a new shifter from AllState gear, but had to source the tower from else where. Pro tip: DO NOT BUY FROM DEADJEEP IF YOU’RE IN A HURRY!!

 

or also if you don’t like being lied to. They’ve been giving me the run around for several days now, FINALLY got a tracking number….,BUT, it’s just a “created label” with no actual movement. If it wasn’t for the fact I can’t find a tower anywhere else, I would’ve canceled my order already. Plus this things got a long ways to go so I’m trying to be patient and wait. 

[howeitsdone]

Nice to see another Utah member! I take it you're much closer to the city lol

 

DeadJeep does take a reaaalllyyy long time. I might have waited almost 3 weeks for a 4x4 indicator bezel. Lady kept emailing me it would ship and, like you, just a label that sat. But you'll get it eventually.

 

The AX15 sounds like a score! How is the interior?

 

Be sure to post the VIN in that forum section. You'll get a factory build sheet that's pretty cool!

[Diesel_Zuk]

17 minutes ago, howeitsdone said:

Nice to see another Utah member! I take it you're much closer to the city lol

 

DeadJeep does take a reaaalllyyy long time. I might have waited almost 3 weeks for a 4x4 indicator bezel. Lady kept emailing me it would ship and, like you, just a label that sat. But you'll get it eventually.

 

The AX15 sounds like a score! How is the interior?

 

Be sure to post the VIN in that forum section. You'll get a factory build sheet that's pretty cool!

Interior is not horrendous. But could use some love. 
 

I got this freezer center console from an auction for $25 I’m hoping I can integrate with some buckets!

 

where are you located in Utah? I’m in Springville. I’m planning on a flatbed but if you know of a shortbed anywhere my ears are open to the idea!

[howeitsdone]

Looks about how mine did! lol

 

I'm way out in Vernal. Knew you were in the city because you have access to a junkyard. Closest to me is in Colorado Springs. So I won't be of much help finding parts. But if you ever need something for the front end there is a Utah XJ group on FB. Couple of guys buy and part them out so there is always something.

[Diesel_Zuk]

I’m planning on the 97+ front end swap, plus doors, this little beauty is staring at me and I’m not excited about it. When I swap strikers I’ll have to repair this. 

[Diesel_Zuk]

8 minutes ago, howeitsdone said:

Looks about how mine did! lol

 

I'm way out in Vernal. Knew you were in the city because you have access to a junkyard. Closest to me is in Colorado Springs. So I won't be of much help finding parts. But if you ever need something for the front end there is a Utah XJ group on FB. Couple of guys buy and part them out so there is always something.

Oh nice! Sounds good! A friend of mine’s dad used to, maybe still does, own the car quest in vernal. But I’m not real familiar with the town myself. Thanks for the advice, I’ll check it out!

[Diesel_Zuk]

Picked up a 97+ front and, and a TJ rock trac tcase that needs a rebuild and a shell. And traded my bench for buckets.

[Diesel_Zuk]

Got my front end kinda on. Need to get some new clips for the torx bolts though, and need to figure out how to secure the front of the fender to the core support, the early style brackets didn’t work so I’m assuming I need 97+, which I didn’t get. Also I need to wire it all up. 
 

 

mounted up my tires and threw them on with the spacers for effect even though I still got a lot of work to do.

[Diesel_Zuk]

Engine pulled, stand-alone harness about 90% completed, adapter plate ordered, and got a new case for the 241OR. New case didn’t come with an oil pump, and old case was shattered, so I swapped them, which everybody says is a BIG NO NO. Why? Because then it won’t be centered. With the output shaft bearing. 
 

 

Let me tell you something though….the difference is about 11 thousandths between the output shaft, and oil pump housing. I threw a new bearing on, flipped it so the shaft is vertical, left the pump loose, shimmed it with a soda can, and then tightened it down. It’s smooth like butter!

[Pete M]

with a bit of creativity, beverage containers are super useful things.