jeepdreamer
Expedition Leader
Do you run it directly or through an air tank?
98 XJ 5.3 Swap and Other Stuff
- Thread starter stomperxj
- Start date
stomperxj
Explorer
Last edited:
stomperxj
Explorer
I've been working on wiring a lot lately. What a pain in the ***.
Plug for the back side of the cluster:
I ran all of my gauge signal wires through the main firewall connector. After thinning out the Jeep harness I had enough wires left over that were unused to do so.
Laying out the GM harness:
More later-
Plug for the back side of the cluster:
I ran all of my gauge signal wires through the main firewall connector. After thinning out the Jeep harness I had enough wires left over that were unused to do so.
Laying out the GM harness:
More later-
stomperxj
Explorer
Well I came across a mistake I made yesterday. I put the manifolds in and they fit fine, plenty of clearance. Then proceeded to build the motor mounts without checking fit on the manifolds at all. Passenger side hit the motor mount so I had to notch the mount down about 3/4" and about 2.5" wide. I cut out a chunk with the plasma and used a piece of pipe cut in half and spread out to fill the gap. Oops...
More this weekend hopefully-
More this weekend hopefully-
stomperxj
Explorer
Thanks Mitch!
Since I have been working on wiring I thought I'd show my gauge cluster. I actually built this last fall before I even bought my motor/trans. I decided to go with Intelitronix segmented LED gauges for a couple reasons. I wanted to do something a little different and I didn't want to spend the money for Autometers.
A few words about Intellitronix. Definitely cool gauges but the whole ordeal was a huge pain in the ***. I ordered my gauges from their eBay store. When they showed up some of the LEDs had varying brightness and the OIL gauge lettering below the numbers was crooked. I emailed the company and sent the gauge back on my dime. It took about 6 weeks to get a gauge back from them. Then I noticed some of the other gauges were not right so I called and talked to a gal there. Long story short it took 7 different shipments of gauges and nearly 2 more months to get all the gauges I needed with the correct color, correct lens tint etc... Their QC absolutely sucks donkey nuts. They are Made in Murica and have a lifetime warranty on them though.... /rant
I modified the plastic surround so I could fit the entire large gauge bezels inside the cluster. I went to a local plastic outfit and asked for glue that I could use on the surround and since it is made from Polypropylene nothing will stick to it. So I cut the surround apart and then used a soldering iron to "weld" it back together. I made a backing piece from .090 5052 aluminum sheet and then covered it with some carbon fiber vinyl for some bling. LED indicators are from Amazon and I got my CEL from Painless I think.
I used a 35 pin connector I got from Digikey for the wiring. I used 32 of the 35 pins. Then made a small enclosure for the connector out of some .035 aluminum sheet.
Anyway... Pics:
jeepdreamer
Expedition Leader
Sick... just freakin' SICK! Wish I had just an iota of your skill.
Sent from my SM-N910V using Tapatalk
stomperxj
Explorer
HercDriver
Adventurer
:bowdown:
stomperxj
Explorer
So I've been fighting some wiring gremlins lately and just got a couple figured out and a couple more to go. The GM harness appears to function properly now. I was missing a ground and finally tracked it down yesterday. Apparently I forgot to label it. Now that it is hooked up I get power to the fuel pump relay trigger wire and the throttle body works.
Anyway..... Here's some pics of a transfercase experiment I am working on. Hopefully it works
Anyway..... Here's some pics of a transfercase experiment I am working on. Hopefully it works
Overland History
Wanderluster
I really wish I had some of your electrical knowledge and access to the machinery that you do!
This is an excellent thread that we can all learn a lot from!
If you feel the need and/or have the time, I wouldn't mind you getting even more technical with info and pictures. Not only do I have an endless capacity for useless knowledge(well, useless when applied to my own build), but in 10yrs, someone may value this thread greatly doing a similar swap.
Keep up the great work!
This is an excellent thread that we can all learn a lot from!
If you feel the need and/or have the time, I wouldn't mind you getting even more technical with info and pictures. Not only do I have an endless capacity for useless knowledge(well, useless when applied to my own build), but in 10yrs, someone may value this thread greatly doing a similar swap.
Keep up the great work!
stomperxj
Explorer
Thanks!
I really wish I had some of your electrical knowledge and access to the machinery that you do!
This is an excellent thread that we can all learn a lot from!
If you feel the need and/or have the time, I wouldn't mind you getting even more technical with info and pictures. Not only do I have an endless capacity for useless knowledge(well, useless when applied to my own build), but in 10yrs, someone may value this thread greatly doing a similar swap.
Keep up the great work!
Thanks Baja - I'm trying to document this build as best I can for future swappers
Did some work on the transfer case this weekend. I picked up a first gen S10 231 to get my input shaft and 6 pinion planetary. Just for reference I was reading a couple S10 forums and a few guys said that all of the original body style S10 231 cases (82-93) have 6 pinion planetaries and wide chains. The downside is its the old style gear cut so it may be a little louder than the newer style. Everything I have read says the gear cut changeover year is 94 so if you are using the older style like me grab a 93 or older case or 95 or newer if you are using the newer cut.
Below is a comparison pic of the 3 different input shafts I have come across. Far left is the 27 spline input, wide bearing (BD50-8), 6 pinion planetary out of the S10 case. Middle is the 23 spline input, narrow bearing, 3 pinion planetary out of my original 98 case. Far right is the 23 spline input, wide bearing, 3 pinion planetary out of the 93 case I picked up this past weekend.
These next couple pics are of the difference in gear cut in the planetary pinion gears. you can see the older pre 94 cut has a wider crown on the teeth vs the post 94 narrow crown.
Getting the needle bearings out of the rear of the case is a pain in the ***. I used a Dremel and a few sanding drums to sand down the outer race until it split and I could knock it out with a small slide hammer.
I'm pretty fortunate to have a good friend that rebuilds transmissions at home as a side business so I called him up and took all my parts out to his hot wash tank.
All the clean parts ready to drop in the case. I had to order a couple more bearings and one seal which should be here by the middle of the week and then the case can be final assembled.
This is a pic of the OEM shift comb vs the 2 low comb that came with the kit I bought several years ago from DC4WD.
And this is a screen shot of the adapter ring I need to make. It is very similar to FrankZ's adapter plate he made. I haven't decided if I want to make it out of aluminum or steel yet. Any opinions on that?
I uploaded another video to my channel showing the custom tail shaft work including some amateur machining porn
Check it out if you want: https://www.youtube.com/watch?v=LIXx4JCMO5QMore later this week.
-Jess