YJ Wrangler Expedition project

[96discoXD]

I'll be running a carb'd motor with an edelbrock offroad carb for now, and may switch to a TBI setup down the road. I'm doing the carb setup because it's nice and simple and I'm doing the conversion on a tight budget.
I'm picking up a rebuilt 700R4 trans and NP231C transfer case this coming Saturday so I won't need any adapters for the trans/TC. The mistake most guys make on the V8 swaps is paying Novak or AA for adapters that aren't really necessary.
My dad already has a nice rebuilt 350 sitting in his garage that I can get cheap, so I'll use the AA bolt in engine mounts, a 22x19" aluminum radiator, a plate-style cooler for the trans, and cable shifter for the 700R4 and a modified shifter for the TC. Some guys have been able to retain the stock driveshafts with this configuration as well. I do plan on either adapting the stock airbox to the carb inlet if there is room to retain it, or building a custom airbox that will allow me to maintain the functionality of the ARB snorkel too.
I will eventually swap a 8.8 rear into the YJ as well.
I agree that a V8 isn't needed, but it would cost me just as much and take just as much work to swap in a 4.0 at this point based on my scenario. I have a 2.5 4 cylinder right now with a gimpy AX5, so the engine swap was a foregone conclusion.
Big Al, if you have that diagram it would be great. I'm not sure yet what wiring I can use and what I will need to modify, but the beauty of the carb'd SBC is it doesn't require much wiring to run it, and if I swap to TBI down the road stand alone wiring harnesses are readily available.

My primary rationale for the V8 swap is so that if I have this thing loaded down with gear for an expedition or week-long camping trip I will have no problem keeping up with traffic on the highway or with getting up any hills on trails. Most guys that have gone V8 can just put it in low range and practically idle over obstacles on the trails.

 

[Root Moose]

Yeah, sounds like you have it covered. In my case I have the converse setup (a relatively low mileage, running XJ with a rusted out body lying around). I was actually hoping to get the engine swung out this past weekend but the holiday weekend conspired against me with my queue of work in the garage.

Youa re correct on the adapters thing. There is no need if you use GM from stem to stern. You can even mix and match NV231C and NV231J parts if you wanted. For example, if you stumbled across a cheap SYE's J case for sale. Or if you needed the Jeep specific speedo gear or VSS setup to drive the Jeep speedometer.

Consider doing some weld in engine mounts. The AA bolt in "cradle" type mount works but it is a bolt in to one place kind of thing. You do not get any flexibility with regard to placing the engine in the engine bay. It may or may not matter but from my perspective I like the idea of having the flexibility to offset the drivetrain to the left or right as required. It may help with prop shaft angles depending on what axles you end up going with (for example).

Again, just some thoughts. I've put a lot of thought into this in the past so I'll share what I've read while I can still recall it.

Back to wrenching...

 

[BigAl]

yj - b5 (black) ground
yj - d4 (red) 12v ignition switch
yj - d5 (yellow) Ignition switch "start/run"
yj - g5 (green) 12v from ignition to starter

 

[96discoXD]

Thanks for some well thought out advice, I do appreciate it.
I'm probably going to do a bit more research into doing TBI, but since I can get a good used edelbrock carb from my father for $50 and spend $13 for the off road needles and seats, I will probably just run that for now for budget reasons.
Big Al, thanks for the pinout information, I'll verify if my '94 is roughly the same, but that definitely gives me a good starting point.

 

[x32792]

:Astrologist:You might want to look into AC with that hardtop. I like what you have planned I'm doing something similar with my 95. I just finished the 350/700r4 swap. I just have to get it wired.

Hard top and AC is very nice if you're going long on hot and dusty roads.

 

[96discoXD]

Hard top and AC is very nice if you're going long on hot and dusty roads.

I may well look into that. I'm planning on using this for some trail rides and off road parks, but also for some camping and mild week-long expedition trips with my son, so the AC might be worthwhile.

I'm assuming I would have to go aftermarket though since my jeep wasn't originally equipped. I could probably use the stock compressor from a GM, but I would need all of the other components to make it work.

I am planning on working something out to run half doors with the hardtop though. Modified TJ upper soft doors will match the contour of the YJ hardtop perfectly, so I may pick up a set of those. That would allow me to do trail runs with the half doors and I could just throw the uppers on in case of rain, cold weather, whatever. I figure with half doors and a vented YJ hardtop I should get a decent amount of airflow at moderate speeds, but on the trail it would certainly not make a lot of difference.

Based on my budget it may have to wait a while though.

 

[Root Moose]

FWIW, I took the AC out of a wrecked YJ. Still sitting on the shelf obviously... These Jeeps are beyond simple, it all comes apart easily since there is not a real dash per se.

Now, if you just want the convenience of a "guaranteed to work the first time" AC setup then buy new stuff (Collin's Bros and others sell the whole Jeep specific setup for ~$1k IIRC).

Time = money : it's always a struggle to determine which one to spend.

 

[96discoXD]

I guess I'll keep my eyes open for a wrecked YJ with AC in the local boneyards, but they don't show up often and get picked clean to the bone very quickly when they do.
Since I'm home this morning I thought I would post some quick progress pics. I've modified a 40mm grenade ammo can to serve as a center console which will be lockable, and houses my CB to keep it secure and out of sight. I've also added a smaller 7.62 ammo can underhood on a modified jack mount to carry small spares and a small tool kit. I'll get some better pictures once I have it out of the garage.
Excuse the filthy garage, my son broke his arm and had surgery a few days ago so the jeep and the garage have been on the back burner.

 

[tip]

I'm loving this thread so far! I'd love to find a clean YJ like that.

Cool idea with the ammo cans... What way are you going to rig up a lock?

Keep up the good work!

 

[96discoXD]

Thanks tip. I actually put the lock on already, I just used a stainless steel eye bolt through the front of the latch assembly and put a padlock on it. It's pretty unsophisticated but it will work. I'll probably put some kind of foam or rubber sleeve over the body of the lock to keep it from rattling. I won't lock it most of the time, but if I'm running with no top or my half doors then I'll lock it. The tricky thing with the 40mm ammo can is they have latches on both ends, not a hinge like the smaller cans do. I just had my neighbor weld one latch to the body of the can and voila, instant hinge.
I will also keep all my registration, insurance and other important papers inside so they're secure.
I'll probably make some little dividers or modular drawers that will fit inside to store little stuff like an LED flashlight, knife, multitool, and other misc items.

 

[CoronaKJ]

I like the ammo lock box under the hood idea....might steal this idea for my yj....keep up the progress.

 

[cavedave]

I agree with the others on the storage unit under the hood. I just recently destroyed my stock jack, so now I have a great place for one of these very same boxes. Question, what did you do to the old jack mount frame before you placed the box on it? I recall the jack mount frame being covered in posts and tabs. It does not seem like a sturdy mount for anything other than the jack. Whatever you did, it's working, and I like it.

 

[96discoXD]

I just took the stock mount and used a cutoff wheel to remove all the upright tabs to create a flat mounting surface.
A couple caveats though.
You will need to use spacers to mount the can to make sure that the lid clears the lip on the top of the fender when you open it.
Also, I mounted it with two bolts, but I will be adding a third mounting point between the ammo can and the lower mounting point for the jack mount using aluminum or steel stock to keep it more stable when there is some weight in there so it doesn't flex or bounce around.
I certainly can't take credit for the idea, I took the idea from someone on one of the jeep forums. It is definitely a great spot to store a small tool/spares kit though.

 

[96discoXD]

I thought it was time to post a few better pictures and a quick update. I packed up the jeep last weekend to head up north for deer camp. I made a plywood shelf to secure more cargo in the back of the jeep for now until I can get a modular cargo unit built for the back of the jeep. All in all it worked out quite nicely except for losing fifth gear in the AX5 gearbox on the way home. Fortunately I was just a few miles from home and was able to take dirt back roads in 4th gear. The transmission and transfer case for the upcoming V8 swap are in my garage and the engine is at my father's house waiting to be moved over. I will probably start on the swap soon. Here are some pics of the jeep as it sits now along with a couple pics at deer camp with my awning setup, which was nice to have as the wind and rain were ugly for a while.

 

[Mr. D]

wow awesome progress and work from when you first got the jeep, very impressive job