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1. including new plugs cap rotor air filter and plug cables accompanied this exhaust system installation With the exhaust system upgrade and tune up mileage jumped 2 8 mpg on the highway at cruise Mileage gains tend to vary realistically though the engine now breathes freely and accelerates much better than prior to this work Before investing this kind of effort you might try a major tune up first and see how much of the 2 8 mpg gain is achievable with just tuning As emphasized in the OFF ROAD article periodically tuning the engine and installing a clean air filter will improve fuel efficiency and performance For those interested do tune with genuine Mopar filters and ignition components Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 Worn 66 and 71 Jeep CJ 5 Steering Gears Are you able to rebuild a 66 Jeep CJ5 steering box The chassis is a V 6 type and believe this is a Ross box Is it wise to rebuild the gear Lavin C My 1971 Jeep CJ s Ross steering box needs a rebuild or replacement can rotate the steering wheel 1 3 revolution before the front wheels actually begin to turn have another used box seems tighter but the true condition is unknown Does it pay to rebuild thes2. to 0 100 It is my understanding that lifter preloads should be more in the 0 030 0 040 range my reason for double checking The engine is a stock remanufactured long block from ATK and now has 15K miles on it The vehicle has just over 111K miles and installed the remanufactured engine at 97K The camshaft is within a few thousandths of new specs for lobe height and duration Questioning local engine machine shops has left me with a variety of answers and I m not too sure which ones to trust One shop reassembles everything and doesn t check preloads It seems like this type of engine runs pretty warm although it may be just this particular unit have noticed that after 30 minutes or more of freeway driving at idle the oil pressure drops much lower to 20 25 psi than where it usually runs in town 40 psi Bringing it just off idle brings pressure back up to around 40 psi It appears that this is due to the oil being so hot as though its viscosity really thinned out temporarily Once the motor idles for a while or is off for a bit it returns and stays at the more normal 40 psi Taking the vehicle on extensive or even moderate off road use has the same effect in increasing the oil temp When the engine gets this hot and I notice the oil pressure can also tell that it is much more apt to want to knock ping if am doing something that requires mild lugging at idle Is this high oil temp scenario typical for the 2 5 liter C
3. Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 Moses Ludel s 4WD Mechanixo Classified Ads Each monthly issue of 4WD Mechanixo will feature a classified ad section While commercial advertising is available and very welcome the classified ad section is strictly for readers needs Each ad appearing in the classified section will be viewed worldwide via free downloads of the magazine Website browsers can access the published copy and view your ad THIS WEBSITE GETS A VERY LARGE NUMBER OF HITS EACH DAY Ad rates are available at the www 4WDMechanix com website The issue with your ad will be readily accessible to any visitor who downloads a copy of Moses Ludel s 4WD Mechanixo digital magazine from the website Viewers often encourage friends to check out the ad as well When you choose to include one or two photos each photo will appear in a highly visible 3 0 width with properly scaled height When viewing the PDF version of the magazine readers can increase the size of your photo to get maximum clarity There is no skimping on our ad display sizing or image resolution The photo will draw attention to your vehicle parts or equipment As for text please do the best you can our ad staff will perform light editing as necessary strictly for readability and to make the ad look its best The deadline for classified ads is normally 2 weeks prior to the issue s release date Each magazine releases ar
4. lower gearing kit for your NP231 transfer case or an Advance Adapters Atlas assembly with lower gearing in low range The blueprint rebuild of the A999 can include upgrades of all friction materials and even a mild shift kit for improved shift performance As the torque converter needs a rebuild there is room for a stall speed change here for improved back country performance in terms of compression braking and crawling on rocks Our shop can do blueprint rebuilding of these A999 and 32RH transmissions we take care of the converter work and balancing too DA a DN ee a SNe F w Stock 3 speed Jeep automatic left AW 4 core right Nick you have a rugged TJ nice equipment blueprint build both the 30RH and 32RH series automatics to perform very well in your driving environment An option is the AW 4 conversion mostly using XJ Cherokee components can build an AW 4 to perform well too and you would have the added bonus of overdrive Regarding the AW 4 conversion the concerns would be transmission length linkage and driveline lengths Electronics including the engine management computer also need consideration Some XJ donor models use the same PCM plug and harness features as your TJ Parts interchange to a large degree between the 9 TJs and XJs however the AW 4 uses its own shift controller would build a blueprint AW 4 using premium parts intended for your TJ s rugged service The
5. 0L has an automatic The transmission needs a rebuild We use the Jeep for a combination of street driving and off road wheeling We have the Rubicon in mind I m interested in upgrades you would suggest for the transmission Are there shift kits available Is it possible to change the gearing to provide better wheeling Would changing 1st gear provide some gear ratio upgrades without the need to substantially change axle ratios Sometime in the Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 future also have a transfer case swap in mind which should improve gearing as well Brad P Brad your questions coincide with some of Nick s concerns so l Il start by sharing that the YJ s A999 three speed is a non electronic shift version of the transmission that Nick s TJ uses Both designs have roots in Chrysler s rugged A904 Torqueflite three speed which worked well in full size cars with lower output V 8s While not quite the A727 Torqueflite of renown the 904 did an excellent job for Chrysler and AMC Brad since you already have considered a transfer case swap suggest that unless you need overdrive the quickest means for getting better off pavement performance would be a blueprint build of the A999 with either a
6. metal gauge over factory mount brackets assures stamina Wire is ER 70S 0 035 MIG type Cushions are stock six cylinder YJ parts Later 4 0L bellhousing and clutch release mechanism work nicely This is not a hydraulic release bearing like the OEM four cylinder type Slave cylinder mounts externally Flywheel is stock 2 5L type with a Centerforce II clutch assembly Mopar 4 0L long block a freshly built AX 15 transmission Mopar Performance MPI conversion pieces the crankshaft sensor trigger at the front damper and a factory header pipe make an impressive package Aftermarket EFI uses OEM induction pieces and sensors Rebuilt Mopar starter motor is late Wrangler variety an efficient compact reduction type The engine fits as stock 87 95 inline sixes use similar engine mounts At right is the fabricated mount welded into place at the frame Temporary hardware is for engine alignment The engine is aligned carefully side to side height and angle to assure proper location of weld in mounts This swap is as involved as a V 8 conversion The Wrangler departed from the earlier CJ frame design For the AMC era CJ four six and V 8 applications each year and model uses the same frame The CJs use bolt on frame brackets attached at different sets of frame holes This allows engine interchangeability unlike the YJ or TJ Wranglers eo Added brace plate laps between upper end of frame bracket In place wi
7. the stock bracket holes plus a front bumper bolt hole They extend further forward and offer superior support These aftermarket brackets are a practical solution to the weak factory bracket There are variations on this theme from several aftermarket suppliers 4WD Hardware might be a resource here YJ 2 5L Engine Tuning and Performance Quirks Hello First thanks for the great books Moses and for answering my questions To begin Mopar used to issue a book on Jeep engines and I m not sure how to get a copy Any idea where to get a copy have a 1989 Wrangler YJ with the mighty TBI 2 5L AMC four Brian L The book is Mopar Jeep Engines Speed Secrets amp Racing Modifications for Jeep Built 4 6 amp V 8 Engines published as Mopar part P4529529 It covers AMC design engines winning formulas from off road and compact truck racing of the late 80s Compiled from factory workshop manuals and racing data this is the only official reference to racing these AMC engines If you cannot find a copy through used literature sources secure a copy of the Mopar 1989 Jeep Service Manual a two book set that includes your YJ Wrangler Brian s questions continued My 2 5L has non adjustable stamped steel rocker arms The Federal Mogul stock pushrods for this are 9 486 length and Clevite s are 9 520 What kind of lifter preload should have when it comes to fitment of pushrods I m getting preload ranges from 0 085
8. upgrade You can expect this level of tech support in issues of 4WD Mechanixo Gone is our classic 87 Grand Wagoneer the one restoration project that Mrs Ludel truly enjoyed The 02 Liberty that served the 3 Edition revision of the Jeep Owner s Bible became a partial payment for our long awaited Cummins powered Dodge Ram 3500 4x4 towing vehicle The Grand Cherokee full time transfer case rebuilds scores of 4x4 axle overhaul and upgrade jobs bumper to bumper mechanical restorations of YJ and TJ Wranglers and oh yes let s not ignore the new JK Wrangler which added a half shelf more of Mopar service information to my three bookcases full of Jeep reference material and the projects continue In monthly issues of 4WD Mechanixo you will find professional unbiased answers to your technical or off road driving questions the same level of detail found in my Jeep books and nearly three decades of magazine features Whether your Jeep is a WWII MB a Willys Station Wagon or Pickup a CJ Wagoneer Gladiator J truck Grand Wagoneer YJ or TJ Wrangler XJ Cherokee Liberty Grand Cherokee or the latest JK Wrangler I m here for your vital technical questions and off road driving tips when requested Welcome Solas gual Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Lude
9. 010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 4WD Tech Q amp A Two Jeep Cherokees Need Exhaust Upgrades saw your article on the exhaust upgrade you did on a 99 Jeep Cherokee would like to do the same modification on my 2000 Jeep Cherokee Is this possible Jennifer talked to a Borla specialist Their kit was not tested on the 98 99 XJs will definitely go with the 00O 01 kit Your article will be helpful if run into minor misalignments Thanks for your advice Vago Note Jennifer and Vago refer to my XJ Cherokee exhaust system article in OFF ROAD Magazine When routing the tailpipe between the frame and right rear spring be aware that our XJ chassis has a 6 inch lift kit installed Stock spring arch may not provide enough clearance here Changing a 4 0L Wrangler Grand Cherokee or XJ Cherokee exhaust manifold is a major task In the article show how to save time swapping manifolds Even so this is a complex job that requires the right tools time enough to get the job done right plus cutting welding equipment for the hanger changes For the magazine project used the 1997 Borla XJ kit for our 1999 XJ Cherokee chassis At the time Borla only offered Jeep XJ systems to fit through 1997 esse
10. 1 1 ratio in top gear and a 1 gear ratio of 3 82 1 Your transfer case has a fairly low 2 61 1 ratio While installing lower gearing for low range has gains check with Advance Adapters for a gear kit prefer a T 18 or NP435 transmission conversion for several reasons A common approach is the Warner T 18 a relatively compact truck four speed with a compound low gear and high gear of 1 1 like your current T 176 A popular conversion approach is the Ford 2WD version of the T 18 which has a 6 32 1 1 gear and a 2 gear of approximately the same ratio as your current transmission The non synchromesh compound low gear is usable in both high and low range while 2 3 and 4 gears are each of synchromesh design The T 18 offers more stamina by far than the T 176 If you opt for the NP435 transmission this is even more rugged than a T 18 and has a compound low ratio of 6 69 1 If you do the math on either of these transmissions you find that their gains in compound low gearing are equal to or better than a lower ratio gearset installed in the Dana 300 For AMC era CJ s like yours have outlined this conversion in both my Jeep Owner s Bible and the Jeep CJ Rebuilder s Bible 1972 86 Having rebuilt the Dana 300 steps also covered in my rebuilder s manual would note that the T 18 conversion is not difficult and provides a cost effective solution for making your Jeep more versatile There is also the NV4500 transmission con
11. 4 0L MPI six requires tools welding skill and attention to detail The project is comparable to a V 8 swap The option of subletting this conversion to a shop could prove costly and tie up your Wrangler for a lengthy time This is not a weekend task Four and six cylinder YJ frames have different part numbers Shown is an 87 Wrangler chassis with a 2 5L four the AX 5 transmission a Dana 35 rear axle and an NP207 transfer case YJ 2 5L fours had throttle body EFI from 87 90 MPI from 91 up This 87 still uses V belt drives looking much like the front view of a CJ or YJ 4 2L inline six ki i YL QAS 0 BS 4 wl 2 5L s AX 5 transmission is weaker than AX 15 used with sixes Output spline count differs too Note motor mount positions on the frame rails Six cylinder mounts are further forward Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 Careful removal of frame mounts requires scarf cutting with acetylene torch Slight portions of original bracket material are intentionally left in place to avoid cutting near factory welds Surface grinding is cosmetic A reinforcement weld at sill plate ensures the integrity of the original frame section Side support strengthens L mounts Increase in
12. AW 4 is tough and could hold up well in your application This might be a reasonable way to get a fresh transmission and an overdrive 4 gear It would be necessary to iron out the PCM and wiring issues perhaps an XJ harness and an XJ computer could be the bridge here After testing and proving out the conversion thoroughly if we were satisfied that this is a viable option would consider building up a core bank and peripheral parts for packaging such a conversion Overall like the AW 4 transmission design and believe this could be the fix if a simpler kit approach were possible TJ three speed automatics are tough but lack an overdrive 4 gear for highway driving Another angle is the late TJ 42RLE automatic with overdrive if this is not a major undertaking The 42RLE is a tough unit used in the KJ Liberty as well A donor model would be the 03 06 TJ with low mileage Such a swap begins with a thorough comparison of parts differences between a 97 TJ and the last generation TJ Items would include electronics drivelines shifter and transfer case positioning differences wiring harnesses shift module accommodations and the PCM Powertrain management provides an engine and transmission interface via electronics The sensors cover wheel speed engine load transmission gearing needs and a host of other inputs Today swapping an electronically controlled transmission is as much an electrical challenge as a mechanical fea
13. Lay Cee bs E gt Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 4x4 VI CW by Moses Ludel The F head engine droned with the downshift to 3 gear We were six hours out of Gardnerville dead tired and overdue for a good meal Tonopah and the Mizpah Hotel stood atop the long hill ahead The next day we d be halfway up Monitor Valley by noon with 60 miles of alkaline dust and two ghost towns behind us and another seventy miles of corrugated dirt road between Mt Jefferson and Austin That was 1965 the CJ 5 just months old Since the mid sixties Jeep vehicles have been an ongoing part of our family A trail worn CJ 3A served as the very first restoration project in 1969 By the late eighties when OFF ROAD Magazine assignments called for a project vehicle Project Trials Machine originated from a rusty 781 CJ 5 four cylinder model Much like this month s feature a 2 5L to 4 0L six swap the CJ s Iron Duke 2 5L four and the light duty T 4 transmission departed early in the project In its place a 4 2L YJ six crate motor and a Dodge truck version NP435 four speed transmission transformed a sluggish light duty CJ 5 into a formidible multipurpose backcountry rig Back in 1987 the Jeep Cup Rally provided wheel time with AMC s first 4 0L EFl powered XJ Cherokee AMC s visionary design became an economical and tractable SUV the trend setter of its class tha
14. bly All adjustments must be on spec before a unit ships from our shop detail the finished assembly in durable epoxy primer and paint color of your choice Cost for this level of restoration and use of NOS parts depends upon the latest NOS prices for the lever shaft and the current condition 6 of your gear Note refer to NOS parts the only assurance of high quality and a long service life is use of original Jeep replacement parts There are off shore repro parts that simply will not meet the standards for fit up and metallurgy Know your parts source and the origins of parts if you attempt to rebuild one of these gears yourself Our shop reconditioned the Ross TL steering gear for this nicely restored 62 Willys Model 475 Photo by Matt Fritz When checking steering play on stock 46 71 CJs look for looseness and wear at the bellcrank tie rod ends and steering knuckle kingpin bearings Some Jeepsters and 70 71 CJs use front mounted Saginaw steering gears with a one piece tie rod between steering knuckles Ross TL applications have the steering gear mounted rearward of the axle and use a draglink bellcrank tie rod to the right side knuckle and a one piece tie rod between the knuckles Make sure you know the origin of the steering play f you opt for a Saginaw steering gear swap there are several concerns 1 mounting the gear properly to the frame 2 using the correct steering linkage and pitma
15. e checking intake and exhaust manifolds the engine pipe and rest of the exhaust system are all new am unable to figure this one out have verified all my valvetrain to the point of degree ing everything out removing valve springs and checking stems to guides for any excessive wear etc Do need to remove my exhaust manifold and check for cracks as the factory manifolds love to crack at the Y s which are hidden by the preheat ducting Is it possible that am seeing the vacuum flutter from the power impulses since it s just a 4 cylinder whereas a 6 or 8 might be smoother Would some small cracks in the exhaust manifold have any effect on intake vacuum Four cylinder power pulses should not be a factor Vacuum flutter can be valves that do not seat completely This can cause engine heat up as well Pushrod length and or valve stem length control the lifter clearance on the AMC fours and sixes The rebuilder must restore lifter clearance and if valve clearance is too close valves will not seat which worsens at higher engine temps This can cause heat buildup and eventually burn valves and seats The EGR not seating at idle low speeds also causes a vacuum drop or vacuum fluctuation Lean fuel mix air leaks ignition timing errors and degrees of spark advance will also affect vacuum Ignition timing is electronically controlled on your engine with sensors feeding input to the module The oxy sensor averages oxygen readings fro
16. e gears Mark Lavin and Mark you have great CJs The 225 V 6 and reasonable gear reduction make these a time honored package The 66 and 71 models should have Ross TL gears with a one piece column Basic and often considered primitive cam and lever two pin gears served the CJs through the Willys and Kaiser period By the end of the Kaiser era Jeep began using popular G M Saginaw recirculating ball and nut gears rebuild the Ross gears for Willys models and Kaiser CJs finding that in nearly every instance there is pin wear Pins on these basic Ross gears wear flat on the sides as they do not rotate and continually press against the cam at the same points on the pins Adjusting the gear is hazardous if the gear has any more than the slightest amount of play on center Off center there will be backlash and this is normal The gear s adjustment is over center to eliminate play only in this zone of steering Customarily the project begins with hot cabinet washing and glass beading of all hard parts before inspection In the build the sector lever bushings are replaced and fitted precisely for a long service life A new lever shaft seal service of the upper lower worm cam bearings and replacement of the sector lever shaft with a new NOS item take place before buttoning up the gear with a new cover gasket Adjustments of the worm cam bearings and over center preload are critical to the safety and lifespan of the gear assem
17. e of six cylinder fan and fan clutch Alternator and brackets are from original 2 5L engine 4 Power steering pump is Mopar rebuilt unit for six cylinder engines Radiator and fan shroud are for six cylinder engines Stock power steering requires slight modification to return hose pipe length Engine package looks like stock 94 95 YJ 2 5L crank sensor left mounted near flywheel At right is a Mopar Performance 4 2L EFI conversion damper with crank sensor bolted to a bracket at the oil pan Fuel pump in 87 YJ 2 5L gas tank is replaced with 91 up MPI high pressure pump Fuel lines and an MPI pump MPI wiring and a 4 0L engine computer complete the job Mopar s EFI Conversion Kit for 81 90 4 2L sixes is built around OEM 4 0L MPI components providing a new engine wiring harness coil the computer fuel pressure regulator all new sensors injectors and fuel rail a throttle body air cleaner and intake manifold This package approach is an option to the recycled 4 0L Wrangler or XJ engine with a used computer and wiring harness details to sort out 91 up exhaust plus new drivelines with a slip yoke eliminator will round out the chassis work Before undertaking this swap consider the costs labor and needed skills Weigh this swap against selling your 2 5L YJ and purchasing a clean 4 0L YJ or TJ Wrangler Another option is to supercharge the 2 5L four Do your homework before plunging Copyright 2005 2
18. ically as the valve stem to rocker arm gap with piston at TDC of its compression stroke both valves closed and seated the hydraulic lifter collapsed without any oil in the lifter Specified clearance should account for the valve rocker arm ratio The stock ratio is 1 6 1 for a 1989 2 5L Jeep engine The blueprint build of an AMC inline six or four should include cutting the installed valve stem heights to compensate for both the cylinder head resurfacing and the amount of valve seat inset from reconditioning the valve seats A bled down clearance of 0 085 0 100 at the rocker arm to stem gap is not out of the ordinary for modern hydraulic lifters Engines like Ford s FE big block V 8s rely on pushrods in various lengths to correct lifter clearances Mopar manuals do not offer a specification they assume that the cylinder head has not been surfaced excessively pushrod lengths are correct head gasket thickness is right and the valve seat depths and valve stem heights are correct It s wise to confirm this and check actual bled down lifter clearance if possible Engines need adequate valve clearance to permit valves to seat Shorter Federal Mogul pushrods may be for remanufactured engines with a surfaced cylinder head and ground valves and seats If your 0 085 0 100 is clearance measured at valve stems to rocker arms with the lifter plungers collapsed note that Ford FE V 8s with a 1 73 1 rocker ratio and no
19. icon 4 10 1 axle ratios with 31 OEM tire diameter 2667 crankshaft rpm 2 Stock Rubicon 4 10 1 axle ratios with 33 tire diameter 2506 crankshaft rpm 3 Retrofit 4 56 1 gears with 33 aftermarket tire diameter 2787 crankshaft rpm 4 Retrofit 4 88 1 gears and 33 aftermarket tires 2982 crankshaft rpm 5 Retrofit 4 88 1 gears and 35 aftermarket tires equal 2812 crankshaft rpm Note that the closest ratio for preserving stock like performance with 33 diameter tires is 4 56 1 The slightly higher engine rpm indicates a gearing advantage that offsets the added weight of hefty accessories 4 88 1 gearing would raise crankshaft rpm even further and provides better performance in terms of acceleration the ability to stay in a higher gear without lugging the engine possibly better fuel efficiency and an improvement in compression braking 35 diameter tires also gain slightly from 4 88 1 gearing Given the real world cost for labor and parts to install 4 56 1 or 4 88 1 axle gearing always advise owners to be prudent If you find that the 4 10 1 gearsets work okay with 33 tires and your driving conditions it might be smart to adjust for the speedometer error and call it good 4 56 1 or 4 88 1 gears or any other choice may require a slight speedometer correction The taller gearing effect with 33 or 35 tires and stock 4 10s does place a greater load on the clutch and reduces the compression braki
20. l s 4WD Mechanixo Digital Magazine Volume 1 February 2010 EFI Six Cylinder Swap 1987 90 YJ Wranglers were available with a throttle body EFI 2 5L four cylinder engine or the carbureted 4 2L inline six cylinder option In 1991 Chrysler switched to MPI on the 2 5L engine and replaced the 4 2L with a 4 0L MPI six The 2 5L four derived from AMC s rugged inline six cylinder designs proved its exceptional stamina for two decades powering many CJ models Wranglers and XJ Cherokees With the addition of large tires a winch a hardtop gas cans and hefty aftermarket bumpers the YJ Wrangler can tip the scale more than 700 pounds over stock curb weight Despite lower peak torque and horsepower than the sixes the 2 5L is a peppy engine easily handling most low range four wheeling chores For better highway performance and light towing the inline sixes do a better job The 2 5L develops its peak torque and horsepower at a higher less efficient rom than the 4 2L and 4 0L sixes This is most noticeable in hilly pulls and at altitude Under such conditions the four often uses more fuel than a six cylinder engine Given the readily available 91 up 4 0L MPI six cylinder Wrangler and XJ Cherokee engines at recycling yards converting to a six might seem practical However such a swap presents a major challenge Four and six cylinder YJ frames are not the same This applies to TJ Wranglers as well Note Changing a 2 5L four to a
21. m all four cylinders and adjusts air fuel ratio accordingly 2 5L fours are reasonably smooth by nature and shouldn t pulse or surge dramatically This again points to dilution from the EGR or a vacuum leak which can also be caused by an EGR that does not seat properly at idle Make sure that the throttle position sensor is working properly and giving the right voltage readings from idle through open throttle A defective TPS can cause idle roughness fuel mix problems and tip in issues Since you ve ruled out valve timing and lift issues the best diagnostic steps now would be a cylinder leakdown test engine still with each piston at TDC of its compression stroke This will pinpoint any valve leakage or ring seal losses Also check for intake manifold to cylinder head leaks and seepage at the throttle body base and shaft Engine at idle use a non volatile penetrant spray leaks will show up as a change in engine speed Note The Q amp A section welcomes your questions Whether a large or small issue a needed part number service tips for a project questions about the value of a vehicle whatever Questions get answered in the sequence received and when volume is high it can take a while Your patience is appreciated Stove adel Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark
22. n adjustable rocker arms call for 0 100 0 150 gap at the valve stem to rocker arm with the lifter plunger collapsed Ford FE pushrods come in different lengths for adjusting valve clearance Brian s 2 5L tuning issues continued have found on this vehicle a normally energized closed solenoid valve that controls vacuum to both the EGR valve and the fuel vapor charcoal canister When I did the engine change put on a new EGR valve and replaced the rest of the engine sensors Jeep discontinued supplying the G M Rochester vapor canister it appeared to be intact Recent troubleshooting led me to the canister s vacuum operated control diaphragm It turns out that this little rubber diaphragm has holes in it from being 18 years old With a breach in the diaphragm the vacuum that is constantly applied at the canister purge port can leak through and back feed through the diaphragm to the canister s purge signal port Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 Instead of the EGR solenoid valve controlling the vacuum to the canister s purge signal port there was vacuum continuously coming from it This was no real problem except that the EGR valve is also tee d into the line for the signal port When the cani
23. n arm plus 3 fabricating the steering column support if your original column ran from the gear to the steering wheel In my Jeep CJ Rebuilder s Manual 1946 71 show the steps for rebuilding a Ross gear like yours and also outline the steps for converting to Saginaw manual steering Historically Advance Adapters has been a source for Saginaw steering conversion kits for the vintage CJs Their catalog can also be useful for identifying the parts needed If your CJ has collectible value or you wish to maintain a stock profile proper restoration of the Ross TL Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 steering gear can add years of safety and driving satisfaction To eliminate the more primitive gear design and busy bellcrank draglink and two tie rod steering linkage consider the Saginaw conversion Late CJ 7 Planning Some Gearing Gains have a 1985 CJ 7 with a 258 6 cylinder engine T 176 transmission Dana 300 transfer case 3 73 gears and 31 tires The Jeep is too high geared in low range I hear there is a kit for the Dana 300 to lower the gearing in low range Where to get one What are the options George George your CJ 7 sounds virtually stock with the exception of 31 tires The T 176 has a
24. ng effect so adjust your driving 4 F accordingly if you stay with 4 10s a ke if a Rites Ihe 5 he Ae eee 4 A Before and after poses of the 04 TJ Rubicon 6 inch lift is clearance for 35 diameter Toyo tires Photos by Joe M Note For those puzzling over why there is not a perfect axle ratio to compensate for say a 33 tire retrofit the answer is very simple Axle ratios available for Dana 44 axles would be 4 10 4 27 4 56 4 88 5 13 and 5 38s The 4 27 1 gearsets make for 2610 crankshaft rpm at 60 mph in 4 direct gear of the NV3550 transmission with 33 diameter tires This is still slightly overdriving when compared to 4 10s with stock 31 diameter tires Since there is no gain and 4 27 1 ring and pinion gearsets are scarce running slightly lower numerically higher gearing of 4 56 1 makes better sense Because overdrive transmissions use various 5 or 6 gear ratios like to use a 1 1 4 gear ratio for illustrating rpm For the curious the NV3550 has a 22 overdriving 5h gear ratio rated as a 0 78 1 Troubled YJ and TJ Automatic Transmissions have a 97 Jeep Wrangler with a 32RH automatic Currie high pinion 9 axles and 4 56 1 gearing with ARB lockers three speed transfer stack box and stock 4 0L engine need professional advice or suggestions about the best option The 32RH has been good but it has to come out So what would you do Nick My 91 YJ 4
25. ntially kits still supplied to Mopar Performance The Borla header is identical for TJ and late XJ applications including the 99 model Borla s 97 XJ package includes the Borla header header to cat pipe a performance muffler and a new tailpipe plus high quality clamps For peak performance added the Random Technology catalytic converter This package turned out to be a good approach Only four modifications were needed to fit the system to this 6 lifted 99 XJ chassis 1 a modification to the head pipe and cat support bracket that fits at the transmission mount 2 careful routing of the tailpipe with a drop bracket to relocate the attachment point for the axle position tailpipe hanger 3 making an offset bracket to position the tailpipe away from the fuel tank at the tank position hanger and 4 careful routing of oxygen sensor wires and wires from the crankshaft flywheel position sensor Keep wires and plastic convolution shield routed away from the header heat As for gains from this installation Borla s superior quality pieces replace the crack prone factory header and a stock head pipe that is highly restrictive Dyne tested Borla s scavenging gains are legend For quality and fit Borla is tops If the stock exhaust manifold has a crack the Borla system is a very wise replacement In terms of installation difficulty a header swap is complex just like replacing a stock manifold Be aware that a major tune up
26. ould the EGR valve and flame temps too high create abnormally high coolant and oil temps tried a new EGR valve which didn t seem to fix the temps Should install an oil cooler The vehicle sees 90 degrees F to 45 degrees F If an oil cooler is called for which style may perform better one with an electric fan and thermal switch or an older fashioned unit with a built in thermal valve assembly Brian oil temperature does play a role here The normal factory rated oil pressure for a 2 5L four Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 of your vintage is a minimum of 13 psi 600 rpm and maximum of 37 75 psi 1600 plus rpm Normal at an 800 rpm warm idle speed is 25 35 psi which your engine may also achieve Despite the drop you describe at idle when hot this is still adequate for lubing the engine An engine oil cooler unless thermostatically controlled would be overkill in your cold winter conditions If you do either kind of thermal control make sure that there is no winter issue with oil temps being too cold Also if you want to know how hot the oil is actually getting try using an infrared sensing thermometer to check the surface temp at the oil pan after running You can spot check the engine at
27. ound the first day of each month Ads can be run by any Jeep enthusiast or private party you can run as many ads per month as you want Each ad will be screened for appropriate language and non commercial nature We also offer highly visible display ad space within each issue of the magazine Yes these are real display ads seen by readers worldwide Not flashing banners click links pop ups or other Internet gimmicks just the kind of display ads that promote your commercial products or services The goal is to provide traditional color advertising laid out within the editorial pages of a widely circulated and respected download PDF publication If you would like to promote your parts or service business the products that you manufacture and sell commercially or vehicles that you sell through a dealership please contact us We present commercial ads in the most professional and artful ways possible You can reach an international audience by associating your products or services with Moses Ludel s 4WD Mechanixo Magazine OUR GOAL IS TO MAXIMIZE EXPOSURE OF YOUR AUTOMOTIVE PARTS 4WD EQUIPMENT OR THE VEHICLE YOU HAVE FOR SALE ADS WILL BE GROUPED TO ASSURE QUICK READER ACCESS HERE IS HOW A TYPICAL AD WITH PHOTO APPEARS IN THE MAGAZINE S CLASSIFIED SECTION 13 Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of tha
28. res on a TJ Rubicon chassis You have probably added an issue that I talk about often at my Camp Jeep workshops the impact on gearing created by the increase in tire diameter from 31 OEM tires to 35 aftermarket tires Any increase in tire diameter will create an overdrive effect The Rubicon s stock 4 10 factory axle ratios work very well with 31 tires Now though your change to 35 diameter tires requires 4 88 1 gearing front and rear axles to restore the vehicle s original Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 driving characteristics Even lower numerically higher gearing than stock is of value when you add the weight of rugged bumpers a winch and extra skid plates Some builders use 4 88 1 gears even with 33 tires however 4 56 1 will actually correct and slightly improve performance over stock when running 33 tires on a TJ Rubicon This is a good formula as long as the transmission has an overdrive gear for any TJ YJ or XJ Cherokee Let s evaluate a TJ Rubicon s direct 1 1 ratio 4 gear an NV3550 five speed application using various axle ratio and tire diameter combinations For simplicity let s use 60 mph as a benchmark for clocking engine rpm 1 Stock Rub
29. ster back fed vacuum it constantly supplied vacuum to the EGR valve This kept the EGR valve always on during every aspect of driving don t know how long this went on but when I recently tested my EGR valve it had failed have replaced it and now am shopping for a replacement canister Even with the canister s interlink to the EGR valve disabled so that the EGR solenoid controlled just the EGR and not the vapor canister and even with a new Mopar EGR valve the engine oil temp still gets so hot that it operates as I ve described Brian the EGR open at idle will dilute the mix and confuse the oxygen sensor into leaning out the air fuel mixture Such a lean mix can cause engine heat up This could cause the oil temp to rise too The EGR is a valuable device that lowers upper cylinder temperatures It is also passive and has little impact on performance with the 2 5L four Brian added this question One last question that don t believe is related This motor has vacuum fluctuations from 20 hg to around 15 hg can hear the idle hunt a bit and see it on the tach up to 200 rpm fluctuation at times sometimes barely any Any vacuum gauge sits there and flutters very fast The vacuum flutter seems to narrow when the engine rpm is brought up yet it still does it to some degree After going through every vacuum line on the engine to hunt for possible leaks hence finding the charcoal canister to be bad and after doubl
30. t For that reason it is sometimes easier to do a G M 700R 4 conversion into a TJ than to use a factory transmission that requires electronic circuits and a PCM interface If owners have an interest in these automatic transmission conversions can cover them in tech features Let me know Heavy Duty Front Shackle Brackets for CJ 7 In the Jeep Owner s Bible you show a shackle that I need for my 1982 CJ 7 Is that a D ring shackle to fit the bracket on my front bumper Where could find that shackle Mike S Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 Mike believe you re describing the heavy duty replacement bracket that supports the front ends of each front spring Full Traction Suspension may still stock these replacement brackets This is actually a heavy duty shackle support not a D shackle attachment point that corrects weakness in AMC era 76 86 CJ front spring frame support brackets The OEM bracket that bolts to the frame and serves as the pivot point for the upper shackle bushings is weakened by a factory punched hole that clears a frame rivet Over time the shackle bracket weakens from load and fatigue and these brackets can bend or even break The heavy duty replacement bracket bolts to
31. t established sales benchmarks Jeep s XJ Cherokee served as the prime bargaining chip when AMC sold to Chrysler Corporation Today the 1984 2001 XJ Cherokees serve as affordable and economical multi purpose 4WDs and trail vehicles In 2005 long time colleague Phil Howell then editor at OFF ROAD Magazine asked if would do a magazine project and suggested the XJ Cherokee My latest book venture was then slated for production at the publisher s offices a YJ TJ Wrangler shop manual featuring in depth coverage of the 2 5L four inline sixes AX 5 AX 15 NV3550 and NP231 gearboxes Saginaw steering plus Dana front and rear axle service These were largely the same components found in the XJ Cherokee For the OFF ROAD project a stone stock 99 XJ Sport was my choice In the June through December 2005 issues Of OFF ROAD magazine this 99 XJ Cherokee metamorphosed into a trail hungry 4x4 In April 06 the XJ proved its mettle at Moab debuting in a Four Wheeler TV trail segment Today the XJ Cherokee and 755 CJ 5 depicted in my Jeep CJ Rebuilder s Manual 1946 71 sit side by side at our shop Spicer Dana axles have been Jeep equipment since 1941 My Jeep Owner s Bible two CJ Rebuilder s Manuals and twenty five years of magazine tech stories have included scores of axle rebuilds and upgrades like this ARB Air Locker Here the XJ Cherokee s Dana 30 front axle undergoes a ring and pinion ratio change and a locker
32. t trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 40 word ad with photo FOR SALE 1987 YJ Wrangler fresh 4 0L EFI six with AX 5 trans ARB s Lockers front and rear 4 56 1 gears 4 inches aftermarket lift with 33 BFG tires Runs great on and off road 6 800 OBO xxx yahoo com or call 619 XXX XXXX Note The ad deadline for the March 2010 issue of Moses Ludel s 4WD Mechanix magazine will be February 20 2010 Please submit your ad prior to that time if possible This will be the first issue to contain widely distributed classified ads Commercial advertisers are welcome to consult with us regarding display ads in the March forward issues of the magazine We look forward to serving your ad needs 14 Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark
33. th plug stitch and lengthy full strength welds the fabricated brackets accept six cylinder YJ type mount cushions Engine block requires left and right YJ style cast brackets that attach to pedestal cushions with a through bolt Copyright 2005 2010 Moses Ludel All rights of copyright reserved Note Jeep is a trademark of Chrysler Corporation Any reference to Jeep vehicles is respectful of that trademark Moses Ludel s 4WD Mechanixo Digital Magazine Volume 1 February 2010 Mounts in place through bolts and nuts secured the engine is stable and well supported at the front Rear mount fits at tailhousing of AX 15 transmission AX 15 s 23 spline output will mate with a 23 spline NP231 or Atlas transfer case Stock skid shield fit AX 5 and NP207 A six cylinder pan would work here The option is to use the four cylinder AX 5 pan and fabricate a mount location for the AX 15 transmission support ER70S MIG wire and hefty steel plate create a strong boxed section On the YJs this skid plate supports the transmission and transfer case Drill holes to match mount cushion holes ey eh IAN Hi fii o ii HAR l i Ml i N Six cylinder MPI engine has considerably more horsepower and torque than the 2 5L four Horsepower is BTUs and a six cylinder well here air conditioning radiator serves Fan upgrade is necessary 2 5L fan left has one less blade and a smaller diameter Note us
34. the valve cover block and timing cover The block surface temp should pinpoint effectiveness of the cooling system Check the radiator for hot spots or lack of flow using the infrared to track heat This can be a simple and effective diagnostic tool As for the EGR valve this valve actually lowers the upper cylinder temps if working properly Its purpose reducing the NOx emissions demands lowering the upper cylinder temps to below 2500 degrees F Without the EGR working properly temps can reach 4800 6000 degrees F much like an acetylene torch always recommend leaving the EGR in place and making sure it functions correctly Pushrod lengths which affect the valve clearance are critical If needed adjustable pushrods are available from Clifford Performance for the 4 2L inline six and other AMC derivative inline engines There are two ways to measure lifter clearance 1 preload which is essentially zero valve lash with the plunger fully extended then add a fixed amount of compression of the lifter plunger and 2 lifter plunger travel measured at the valve stem to rocker arm gap with the lifters plunger fully collapsed Non adjustable stamped rockers usually can only be checked for lifter travel with the plunger collapsed Correct specs for plunger or valve stem clearance with the plunger collapsed fully should be available through ATK or Clifford Make sure you measure clearance at the correct reference point specified typ
35. version that cover in the Jeep Rebuilder s Manual 1972 86 This is the 7 ultimate transmission for strength and flexibility likely overkill for most applications The NV4500 has versions with as low as 6 34 1 first gear plus a 5 gear overdrive on top All forward speeds have synchromesh and an overdrive can improve fuel efficiency More costly than a T 18 conversion the NV4500 is for those who need or want a 1 ton Capacity transmission with an ultra low 1 gear plus 5 overdrive Checklist A TJ Rubicon s Latest Mods Hi Moses The local shop just installed a variety of components on our 04 TJ Wrangler Rubicon I d like to share the list and see if you would add or modify any of the items Full Traction 6 Long Arm Performance Suspension Complete Exhaust System cat back CV Driveshafts HD Engine Skid Plate Steering Stabilizer 3 Way Adjustable Rear Sway Bar M Force Shocks Skyjacker Transfer Case Relocation Bracket Warn Front Rock Crawler Bumper Warn Rear Rock Crawler Bumper Warn Tire Carrier Warn Fuel Tank Skid Plate Warn Differential Skid Plates Warn 2 Receiver Shackle B amp M Short Throw Shifter Mickey Thompson Classic Il 16 x8 Wheels Toyo Open Country M T LT315 75R16 same as the 35 x12 5Rx16 size Thanks for evaluating our Rubicon s modifications We re headed for Moab Joe M Joe this sounds like a thorough list for putting 35 diameter ti
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