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Supertrooper's CJ5 build

Discussion in 'Builds and Fabricators Forum' started by supertrooper, Oct 15, 2010.

  1. Apr 1, 2018
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    I was able to remove the transfer case and transmission from the jeep today. I started to disassemble the transmission and what i found wasnt good.:censored:

    The roller bearings in the input shaft failed and took out the input shaft, main shaft, and 2nd/3rd gear syncro assembly. I haven't finished taking it apart yet but the rest looks salvageable.

    [​IMG]
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    Last edited: Apr 1, 2018
  2. Apr 1, 2018
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
    Aug 13, 2015
    Messages:
    3,112
    That is tragic. :cry:
     
  3. Apr 2, 2018
    tarry99

    tarry99 Member Sponsor

    Northern California
    Joined:
    Oct 29, 2012
    Messages:
    3,770
    No Lube?
     
  4. Apr 2, 2018
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    When i took the shift tower off the fluid was low. There were no fluid leaks on the trans or t case and if to much trans fluid flowed into the t case because they share oil i would think the trans bearings would have failed a lot sooner.
     
  5. Apr 2, 2018
    jpflat2a

    jpflat2a what's that noise?

    Riverside CA
    Joined:
    Jul 30, 2003
    Messages:
    7,749
    bummer
    looks dry as suggested
     
  6. Apr 8, 2019
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    I didnt realize its already been a year since i updated this thread. I ended up rebuilding the T14 and it worked fine but i started researching transmission swaps. I decided on a sm465 and found one cheap on craigslist and rebuilt it with a kit and dana 18 adapter from novak. My original bellhousing wasnt in great shape so i bought a buick to sm465 conversion bellhousing from advance adapters. I was hoping to just reuse the hydro clutch setup but the release fork and pivot are different and with take a little modification to work.
    [​IMG]

    Over the weekend i was able to get the transmission into the jeep and i made a new crossmember for it. I also started cutting the trans cover to make room for the bigger transmission. Im planning on moving the rear axle back 1" to get more tire clearance from the wheelhousing notch then i can measure for driveshafts.
    [​IMG]
    [​IMG]

    A couple months ago i finally got around to adding a gas can mount. I modified a smittybilt bracket and used an old jerry can.
    [​IMG]

    The headers were putting out a lot of heat in the engine bay especially in the summer. I thought about making aluminum heat shields but im not good at sheetmetal work and figured it would just be one more thing to cut up my hands. I saw some videos on titanium exhaust wrap and decided to give it a try. It came out better than i thought it would.
    [​IMG]

    With a little luck i will get the jeep up and running again in time for this years rubicon trip.
     
  7. Apr 14, 2019
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    I hate doing sheetmetal work, took me most of the day to fab up the transmission cover but its done for the most part. Still need to clean up the welds and i cant decide if i want got through the effort to relocate the access panel for the tcase shifter pivot pin.
    [​IMG]
    [​IMG]
     
    Buildflycrash, 47v6, ITLKSEZ and 2 others like this.
  8. Apr 14, 2019
    Framer Mike P

    Framer Mike P Member

    Hopkinton, NH
    Joined:
    Jan 4, 2016
    Messages:
    182
    Looks really nice to me. You could cheat and elongate the access hole and make a long cover.
     
  9. Apr 15, 2019
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
    Joined:
    Dec 17, 2002
    Messages:
    1,991
    Not much room for the throttle foot. I made mine smaller.
    [​IMG] [​IMG]
     
    supertrooper and Fly Navy like this.
  10. Apr 16, 2019
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    Your cover definitely looks a lot better than mine. I dont have much experience making things out of sheet metal and the only sheet metal tools i have are tin snips. The camera angle makes the throttle pedal area look smaller than it really is. The left side panels are at the same spot the original panel starts to curve up next the the pedal, just more vertical. I wanted to angle the rear down some so it didnt look so big but i didnt want to risk ruining the top piece if i messed up.

    What shifter boot are you using? My sm465 didnt come with a boot and most of the generic aftermarket boots are for automatics.
     
  11. Apr 16, 2019
    zinertia2

    zinertia2 "and which part are you keeping?"

    San Diego
    Joined:
    Feb 15, 2018
    Messages:
    58
    Scott
    Is that a pan off of something?
    Dennis
     
  12. Apr 16, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
    Aug 13, 2015
    Messages:
    3,112
    FWIW, Volvo 240 boots are square and made from a heavy rubber that seems to last forever. It looks like it would fit your opening perfectly.
     
  13. Apr 16, 2019
    scott milliner

    scott milliner Master Fabricator

    Seattle Wa.
    Joined:
    Dec 17, 2002
    Messages:
    1,991
    It's the stock 1979 Chevy 3/4 ton truck shifter boot and for the floor cover. I used a cut down TH350 Automatic Transmission oil pan.
     
    txtoller and supertrooper like this.
  14. May 13, 2019
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    I made some progress over the last couple of weekends. The throwout bearing was binding with the new AA clutch fork and was just a hair too long to have proper free play. The flat face TO bearing from AA fixed the problem and after modifying the slave cylinder bracket the clutch works great. When i was setting up the slave cylinder pushrod lenght i think i damaged the bore with the all thread i was using for a pushrod because it started leaking pretty bad and had to be replaced. I made a new push rod with round stock so it cant scratch the bore and threaded it for some adjustment. I redrilled the rear axle spring perches and ubolt plates to move the axle back 1". While i had the axle out i changed a leaking pinion seal and added a braided hose the relocate the diff breather up high in the fenderwell. I welded a tab to the trans x member for the e-brake cable. I bolted on a novak transfercase oil pan. I got a new driveshaft with an extended travel slip yoke from tom woods, very nice quality and the guy i talked to when ordering was great to work with. With the longer transmission and adapter plate i think the front driveshaft slip yoke is near the limit of its travel so ill probably have tom woods make me a new one.
    [​IMG]

    In the cab, i finished welding then painted the transmission cover and reinstalled the steering column and throttle pedal. The sm465 shift lever that came with the trans had some strange bends in it that i would never be able to straighten out so i got a universal shift lever for the sm465 from novak that has no bends in it. I put a couple bends in it and shortened it a few inches and it fits perfect. I used a lokar transmission shifter boot and a dana 20 twin stick boot. The cb radio i had was really basic and i wanted something with more features and was a little more compact. I replaced it with a cobra 75.
    [​IMG]

    I didnt have enough gear oil to fill up the transfer case and transmission so i couldnt do a test drive last night. I still need to change out i freeze plug that has a little leak. Other than that all the things on my "things to fix before the rubicon trip" list are crossed off. But then again, jeeps are never really finished.
     
    Last edited: May 19, 2019
    ITLKSEZ and Bowbender like this.
  15. May 13, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
    Joined:
    Sep 10, 2018
    Messages:
    332
    Great job. Looks amazing
     
  16. May 13, 2019
    Chilly

    Chilly Active Member 2019 Sponsor

    Joined:
    Mar 12, 2007
    Messages:
    1,449
    Are those mastercraft seats? Did you notch the wheel well?
     
  17. May 13, 2019
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    Thanks

    They are empi seats. They are made for old VWs and sand rails. Yes the wheel wells are notched.
     
  18. Jul 28, 2019
    supertrooper

    supertrooper Member

    moreno valley, ca
    Joined:
    Nov 12, 2007
    Messages:
    482
    When i was on the rubicon trip the jeep was running a little hot with all the low speed high load driving. It never boiled over but i did have to stop a couple times on the last day to pour water on the rad to get it cooled down. The electric pusher fan wasn't cutting it anymore so i decided to go to a mechanical fan. I took inspiration from kyle's (norcal69) setup. I got a universal fan shroud kit from summit along with a 15" derale flex fan and 1 1/2" spacer. The shroud was a little too big but i was able to cut it down to fit and came out better than expected.
    [​IMG]
    The new fan definitely flows more air at idle than the electric fan ever did and you can feel the air getting pulled into the grill. There is also alot more air flowing into the engine bay side. The headers were putting a lot of heat into the engine bay even with heat wrap. The engine bay was getting so heat soaked i thought i might have to add hood vents to let the heat out. I think with all the air flow from the new fan will help push the hot air from the headers out of the engine bay. Im also going to relocate the winch solenoid box so it doesn't limit any air flowing into the radiator.
    [​IMG]

    My body damage from the Rubicon was fairly minor. The gas tank skid plate had some rock rash and the transfercase oil pan got a small scrape. Both mufflers got huge dents and were push up against the bottom of the tub. I knew the exhaust was going the take a beating and im surprised they didnt get ripped off when i started using them as sliders. I always wanted to try running the exhaust inside the frame rails again so i bought the block hugger headers from novak but they are backordered for a couple more weeks.
    [​IMG]
    [​IMG]

    The worst was the rear wheel wells. I cut the back of the wheel opening 1 1/2" back before the trip but with the axle moved back and the 33" tires it wasnt enough. The first time the rear suspension got flexed out the sheet metal behind the rear tires on both sides got folded in a few inches. The driver side was the worst. I forgot to get pics before i hammered the metal back into place but you can see the darker line is where the metal was bent in. The sharpie line is where i should have cut the opening at. I got warrior products steel corner guards to help prevent more serious damage to the tub.
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    Last edited: Jul 28, 2019
    Muzikp, ITLKSEZ, Norcal69 and 2 others like this.
  19. Jul 28, 2019
    jpflat2a

    jpflat2a what's that noise?

    Riverside CA
    Joined:
    Jul 30, 2003
    Messages:
    7,749
    Nice work on the fan and shroud.
    I've never been a fan of electric.
     
    73 cj5 likes this.
  20. Jul 28, 2019
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member Sponsor

    Denver, CO
    Joined:
    Jul 18, 2013
    Messages:
    2,186
    Let us know about the warrior corner guards...been interested in them myself...do they have any kind of folded lip to wrap under the sheet metal?

    edit - now that I see the picture better, it doesn't, but still seems like they could be pretty useful
     
    Last edited: Jul 29, 2019

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