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  #21  
Old 04-06-2020, 09:31 PM
JPSwapMohn's Avatar
JPSwapMohn JPSwapMohn is offline
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Location: CO.
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If you have an extra set of hands and back, I would remove the front clip as one unit. It is a bit of a pain to get the front valence separated from the front fenders, etc.

I have disassembled mine several times without the extra help, so took it apart in pieces.
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  #22  
Old 04-06-2020, 10:10 PM
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cu4whln cu4whln is offline
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Location: Canton, Mi USA !
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Quote:
Originally Posted by JPSwapMohn
If you have an extra set of hands and back, I would remove the front clip as one unit. It is a bit of a pain to get the front valence separated from the front fenders, etc.

I have disassembled mine several times without the extra help, so took it apart in pieces.

Thanks for the input ! I think I will go with the full clip removal. Will have to provide beer and pizza for my helpers . . .

I watched your build.. it is AWESOME ! Look forward to when it's "All Done"
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It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #23  
Old 04-07-2020, 07:14 AM
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bkilby bkilby is offline
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Location: Burbank Ca.
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Another vote for Pull clip. Should be a lot faster providing you have the place to store it.
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1974 Cherokee S. It's driving but needs more work. As usual!

Last edited by bkilby : 04-07-2020 at 01:09 PM.
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  #24  
Old 04-07-2020, 11:02 AM
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bigwalton bigwalton is offline
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Join Date: May 25, 2006
Location: MI
Posts: 130
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'77 Cherokee S 4-door - DD patina project
'84 Alaskan Postal CJ-8 - RHD fun driver/trail rig
'98 TJ - DD
'05 Rubicon LJ - DD
'18 Renegade - DD
'99 Ford E350 dually shuttle bus redneck camper/tow rig
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  #25  
Old 04-07-2020, 06:27 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
Quote:
Originally Posted by bigwalton

Hi Eric! I am working on getting "your" 401 out..

Dang it .. no matter how careful I am... Blood. I guess I own it now. [ ref sig below ]

[IMG][/IMG]

A buddy stopped by for literally 10 minutes.. to help me pull the hood. Found the PERFECT place to store it for a couple of months till this is running again. Hey, that's what a roof rack is for, right ?

[IMG][/IMG]
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It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #26  
Old 04-07-2020, 07:28 PM
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bigwalton bigwalton is offline
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Join Date: May 25, 2006
Location: MI
Posts: 130
Nice! Looks like the perfect spot for the good indeed.
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'77 Cherokee S 4-door - DD patina project
'84 Alaskan Postal CJ-8 - RHD fun driver/trail rig
'98 TJ - DD
'05 Rubicon LJ - DD
'18 Renegade - DD
'99 Ford E350 dually shuttle bus redneck camper/tow rig
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  #27  
Old 04-08-2020, 10:10 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
In Today's News . . .

Got the front bumpers removed, and everything under the hood disconnected. Next up: Underbody.. X-member, engine mounts and trans mount removal.

[IMG][/IMG]

Then got the front clip completely loose - except the 2 upper hinge bolts. Now I need some buddies to help lift the front clip off the Jeep. Dang social distancing !

One of the challenges of the day.. removing the 2 front body mounts. Not much bolt access.. and when it is loose? The nut falls down into the frame.. gone forever. Pic is in front of the driver side tire.. above the bumper bracket.There is a small slot to get at the nut.. but very tight.

[IMG][/IMG]

So.. what to do.. what to do? I added some tape on the bottom of my wrench .. after bringing the bolt to the end of the threads.

[IMG][/IMG]

Then, I lined it up and removed the bolt.. the tape trapped the nut in the wrench. Success ! Duct tape saves the day, again.

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #28  
Old 04-11-2020, 10:38 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
Made some progress... I WAS going to remove the front clip as an assembly. Had everything loose.. and then the governor locked down Michigan for ANOTHER 3 weeks!
Can't get anybody over to help remove it ... Soooo - the heck with that.. took it apart

[IMG][/IMG]

Got the front clip disassembled and stored up in the rafters...

[IMG][/IMG]

Was pretty happy with what I found on the frame. Very minimal rust.

[IMG][/IMG]

You know what I hate? Old rusty exhaust bolts.... that you can't reach with any wrench. Got the exhaust cross over pipe off.. took WAY too long. The new owner wants the exhaust as well. I could have cut it off, but oh well.

Also "modified" the wiring. Next owner of the engine/trans/t-case is putting this into a 77 Wagoneer, so he can just match up the wire colors. I am leaving all my upgraded ignition stuff on - this will make it easy to hook up. I am planning to replace the original harness with one from BJs

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 04-11-2020 at 11:38 PM.
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  #29  
Old 04-12-2020, 01:54 AM
rang-a-stang's Avatar
rang-a-stang rang-a-stang is offline
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Join Date: Oct 31, 2016
Location: Camarillo, CA
Posts: 3,490
Ooooooh! This is gonna be goood!!!
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79 Cherokee Chief
(Cherokee Build Thread)
11 Nissan Pathfinder Silver Edition 4x4
09 Mazdaspeed3 Grand Touring
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  #30  
Old 04-12-2020, 08:56 AM
bkilby's Avatar
bkilby bkilby is offline
350 Buick
 
Join Date: Jan 10, 2016
Location: Burbank Ca.
Posts: 931
Looking good Jim. I'd come help but I'd probably be arrested a dozen times for crossing state lines. Lol. When did they start painting the inner fenders the body color?
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1974 Cherokee S. It's driving but needs more work. As usual!
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  #31  
Old 04-13-2020, 10:01 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
Had the day off .. but it was cold and I didn't feel too motivated.. BUT - Did some brake planning. It seems the vacuum pump on the L83 Acc drive may interfere with the steering maybe?

So figured out how to get proper manifold vacuum without the pump. These new engines don't have vac ports like an old school ones. I will have to eliminate the purge valve and then tap that port for a vacuum fitting to supply the brake booster. Then I can remove the vac pump completely.

Also, since the fenders are off, decided to look into the fender well vents. The drainage passages? This is supposed to drain the cowl area inlet during rain. Totally blocked with accumulated crapola. First pic, see the debris hanging out of the drain opening?

[IMG][/IMG]

Hmm, decided to poke around with a screw driver and various things to help clear the drain. Yikes, this is only PART of the stuff that came out. Pic doesn't show how much is there really. Mostly leaves and tree stuff.

[IMG][/IMG]

This is what the drain is supposed to look like... After I cleaned it out. I am going to add some screens in the upper cowl area to keep this stuff from plugging it again.

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 04-14-2020 at 09:56 AM.
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  #32  
Old 04-14-2020, 08:53 AM
bigwalton's Avatar
bigwalton bigwalton is offline
232 I6
 
Join Date: May 25, 2006
Location: MI
Posts: 130
Excellent. The new owner greatly appreciates the effort as he desperately wants that sweet-sounding exhaust
__________________
'77 Cherokee S 4-door - DD patina project
'84 Alaskan Postal CJ-8 - RHD fun driver/trail rig
'98 TJ - DD
'05 Rubicon LJ - DD
'18 Renegade - DD
'99 Ford E350 dually shuttle bus redneck camper/tow rig
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  #33  
Old 04-14-2020, 09:56 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
in Today's News . . .

Gas Tank, Round One:
40 year old bolts were a LOT of fun. Got the skid plate removed, and then worked on the fuel tank itself. Sure would be nice if they had used a few weld nuts. Getting a wrench over the tank and holding it was a bugger. [ Vehicle also has a rear tank, will likely remove that as well. Don't need 47 gallons of fuel on board !]

This stuff was heavy! Working alone was a bit of a challenge. The rubber fuel fill hoses? Hard as a ROCK. Heck, they were hard to cut! After some effort, and reading the factory service manual.. I got it out.

The gauge said 1/8 of a tank. NOPE. I spilled about 5 gallons in the back yard when the tank fell off my makeshift draining fixture. Sorry dear, the grass is prob not gonna grow there! Tank was not in horrible shape actually...

[IMG][/IMG]

Removed the sending unit and fuel pickup. This is what 40 year old parts look like! No wonder I see rust in the fuel filter.

[IMG][/IMG]
[IMG][/IMG]

Interesting find: inside the tank, there is a "fuel slosh" baffle by the pickup. I didn't think our tanks had that? I am very happy there is one! This is a pic DOWN the pickup opening... see the vertical wall? Not rusty. And some crud on the bottom of the tank of course... including the remnants of the pickup screen.


[IMG][/IMG]

Couldn't resist laying the new in tank Holly pump top part to see how it will fit. [It's upside down here] I think it's going to work great. I will detail tank mod and installation later.

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #34  
Old 04-18-2020, 07:37 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
Dana 300 . . .

So I needed a Dana 300 t-case, and friend says, I have one you can have. It's been sitting on the shelf for 30+ years.. but it had very low miles on it. Great. Price was right - Free.

So today I venture out to the storage area, and actually find it.

[IMG][/IMG]

I then went to Dave's shop and we installed the NOVAK 32 spline output shaft for the 6L80 trans. First, remove the gear, then the retaining clip so the bearing can be removed. Old and new input shaft.

[IMG][/IMG]
[IMG]
[/IMG]

Then the shaft and bearing can be removed from the input housing. The press had no problem removing the bearing, then we pressed it on the new input shaft.

[IMG][/IMG]

All installed, really easy. Now for some initial cleanup.

[IMG][/IMG]

An hour of basic cleaning... will degrease and find my POR.

[IMG][/IMG]

Now, one remaining issue.. I need the shaft that holds the shift rod in place. I have yet to find a source for that. Anybody have one they can separate with? it's the cross shaft that the shifter sits on.. has a nut on one end, and washers and cotter pin on the other.

Does anybody make a SINGLE cable shifter? I only see twin stick set ups. Will probably use the stock one, if and when I can find parts.
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #35  
Old 04-19-2020, 06:41 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
No huge news today. But an important one. I spent the day measuring all the various angles of the engine, F & R propshafts, pinion angles as it sits now. It has no vibrations currently with the 4" lift.. so I'll shoot to match these is possible.

Did some basic cleanup on the tank... still lots of crapola floating around in the tank. Need the fuel to evaporate so I can cut the hole for the planned in tank pump module. The tank cleaned up well, no real rust damage .. well, on the outside anyway.

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #36  
Old 04-20-2020, 09:54 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
In todays news :

Worked on a few things today. Looks like 401 is coming out and leaving my garage Sat. Mixed feelings, but part of the process.
Got everything loose.. literally.. the engine is just sitting on the mounts and a jack stand under the t-case.

Worked on prepping the tank for cleaning and coating... Before it goes, I need to remove the locking ring to make a good sealing surface for the new fuel pump module.

The locking ring is spot welded around the edge. I thought I could use a chisel to break the welds .. NOPE. Don't do that. It tore the weld and distorted the edge. I then drilled each spot weld out.. then they came off pretty well.... I flattened each one as best I could with a hammer. LOUD !

[IMG][/IMG]

I used a small pry bar and tapped it under each one.. and they came off. 9 total.

[IMG][/IMG]
[IMG][/IMG]

The Holly directions say to drill a 3 1/4" hole... so I marked it off on the top of tank. Now, as the tank still smell like fuel, I am letting the professionals cut the hole and weld up the 9 holes...

[IMG][/IMG]

I am pretty happy with how this appears to be working out... There is a flat area for the foam seal to sit against.. and it fits in the anti-slosh tub inside the tank. I had to test place the top of the module to see of course....

[IMG][/IMG]

The tank cleaning service will totally clean and blast the tank inside and out.. they coat the inside so it will not rust again. Then, they add a tough durable coating on the outside as well. That's fine with me.. I may not put the skid plate back anyway...
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 04-20-2020 at 10:03 PM.
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  #37  
Old 04-20-2020, 11:30 PM
SJTD SJTD is offline
350 Buick
 
Join Date: Apr 26, 2012
Location: Lompoc and Sunland, CA
Posts: 1,455
Idunno about welding the holes. Isn't the tank plated with lead or a lead alloy? My tank's plastic but other steel tanks I've messed with were. If so maybe solder instead?
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  #38  
Old 04-21-2020, 06:14 AM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
Quote:
Originally Posted by SJTD
Idunno about welding the holes. Isn't the tank plated with lead or a lead alloy? My tank's plastic but other steel tanks I've messed with were. If so maybe solder instead?

Hmm, I don't know? It appears, if anything, there might some galvanizing inside the tank? I will let them make that call. Snow and ice here.. I think I will wait for a better day to drive an hour each way . . .

Actually, the module has a thick foam gasket that is probably wide enough to cover the holes. I was hoping the required opening would eliminate the holes.
This is a pic of the underside of the module - See the foam gasket? It's maybe 1/2" thick.

You can also see the 5 cams that rotate out and capture the underside of the tank as you tighten them.

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #39  
Old 04-24-2020, 05:50 AM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
Spent some time getting the Dana 300 ready to install... First, you remove the stock 4wd adaptor.. then I reused the bolts to install the Novak adaptor to the trans... ( This is a dry adaptor btw )
Next, you install the new studs with lock tight in the t-case.

[IMG][/IMG]

Then played with the various clocking positions trying to decide which one to use... The front output is REALLY close to the trans and heat shield... I decided to remove the heat shield at this point.

[IMG][/IMG]
[IMG][/IMG]

Then .. I couldn't-case in get the transfer case to fully seat? At first I thought it was me.. 85 lb t-case.. jiggling it around trying to get it on. Nope.

Then I did some measuring. Hmmm, it seems the trans output shaft is too long? It bottoms out on the newly installed input shaft? Going to have to call and ask Novak about that.
It says a 4WD trans should bolt right up with this kit? As this is a 2018 6L80, maybe GM made a change to the output shaft ? No big deal, I guess I can cut some off the shaft.

[IMG][/IMG]
[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280
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  #40  
Old 04-25-2020, 07:02 PM
cu4whln's Avatar
cu4whln cu4whln is offline
350 Buick
 
Join Date: May 16, 2008
Location: Canton, Mi USA !
Posts: 1,230
In Today's News . . .

401 be gone ! Today we removed the original 401 and sent it to a good home. Going into a 77 Wagoneer- "Mater".

[IMG][/IMG]

[IMG][/IMG]

Eric is happy !

[IMG][/IMG]
__________________
It's not yours 'til ya bleed on it . . .

1977 "401" 'Da Chief
1979 Chero: "Madness" [Sold]
1985 CJ : Renegade -locked and loaded
2005 Unlimited Rubicon - Built
2001 XJ : Driver 2016 JK 2 door

'Da Chief here: http://www.ifsja.org/forums/vb/showt...ighlight=chief

Round 2- LT Swap: 'Da Chief:
http://www.ifsja.org/forums/vb/showthread.php?t=188457

"Madness" build here:
http://www.ifsja.org/forums/vb/showthread.php?t=89280

Last edited by cu4whln : 04-25-2020 at 07:28 PM.
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