Project...Kahuna 66 cj6

I should post a pic of my "new" blingy mirrors...

 

got the brake system finished yesterday.......the new booster had a threaded rod on the interior side, I needed to mod the old rod/fork to work with it. I cut it down and used a grinder to get it to the correct size then threaded it the match the new booster rod. Put a coupler on it and had it licked


I finished up the install of the new saginaw box as well.......the pressure side hose drips a bit, guess I'll need to have it replaced eventually
Took it out for a spin today.....it runs like a scalded cat ............really looking forward to doing a run, but DD duties will suffice for now
Jim S.

 

I went to a 4X show n shine last weekend that included 20 miles of freeway driving. I could not get the OD to engage so ran 65mph @ 3500rpm's.
Wed. eve when I got home from work I had planned to pull it to see what was going on. Got out of the Jeep when I got home and saw antifreeze rolling out from under the front mehh. The fan had nicked the bottom rad outlet and I had a tiny spray......I pulled the radiator then decided to pull the OD, while under the Jeep I could see the trans cross member was loose no doubt contributing to the rad problem. The OD had a syncro that was messed up as well as a bearing damaged

I ordered the parts to repair the OD from Herm on thurs. morning and they got here in todays mail

Got everything put back together and installed the unit this afternoon.....(getting easier w/ experience)

I decided to drop the radiator about 1" to give myself a little more clearance by the lower outlet. The old side mount wasn't gonna work anymore so I fabbed up some brackets to make a "saddle for the bottom of the rad to sit in. I used some material left from my winch mount plate

I welded them onto my cross member so the rad could sit in them without being secured, and added some rubber strap under the radiator.....the rad can float so the flex won't tear it up


All in all a good day....Od shifts well now, I'll put it through it's paces next week
Jim S.
OBA and the 8274 winch coming in the future

 

devil is in the details.......I've been told by several people that I needed to shield the air filter from the hot air from the fan. They say it'll mess up the readings to the computer and cause performance issues w/ the 5.0.
I started with a galv. sheet (probably 18g) and began cutting and forming, ending up w/ this

I bolted it to the fender well so it'd block the direct flow from the fan


guess we'll see how it works in the coming days
Jim S.

 

Dayum! You made a whole Lincoln!

 

R)...hope the fender skirts I need to make for that boat go as well
Jim S.

 

so how did you accomplish that?......through the inner fender seems the only option
Jim S.

 

my tires were rubbing the shocks at full turn in the front.....I didn't want to lose any turning radius so I removed the shocks and cut down the covers...
you can see in the first pic how bad the rubbing was



should help quite a bit....I checked for sag/compressed measurments and my bump stops and shock length are fine
Still battling with clutch adjustment.....it's making a horrible noise on 1st gear launch
Jim S.

 

well I dropped the trans/tc today. I then pulled the bell housing and pressure plate/clutch. I found the problem

the bolts on the flywheel were shiny as were the springs on the clutch....they were making contact and the noise. I took the clutch into napa so I could make sure the new one was gonna match. While talking to my buddy he asked what bolts had I used on the flywheel, I said the ones that came with the motor....he said the ones that were used for the auto flexplate?" yea I say those.....I then learned something new, the bolts from the flexplate /auto are differant (taller head) than the ones for a flywheel/manual .....I purchased new arp bolts and the new clutch, tomorrows project
I may have solved the motor problems I've been having as well.....found the cable that grounds the motor to the frame/battery disconnected....figure that may be effecting the sensors/computer....keep your fingers crossed
Jim S.

 

you two are funny.....it'd drive me nuts way before the "wear in"

live and learn is my plight, or learn the hard way I should say. I replaced the flywheel bolts then went to work on the clutch. I could not get the trans/tc to index with the clutch, after half a day I pulled the clutch and checked the disc, it wouldn't slide over the input shaft of the tranny. Now I had checked the old/new discs at Napa to be sure they matched, but alas not close enough .
I measured the new 10" disc....10 spline 1/16".(standard Ford).....measured the old 10" disc/input shaft...10 spline 1/8".......we checked the books at Napa, even the Jeep T18 didn't match
The solution was to keep the pressure plate and order a clutch disc from a 77 Olds ( 10" 10 spline 1/8")
This jeep thing is a education that's leading me to the brink of insanity mehh
Jim S.

 

took awhile to get everything back together (kids busy schedules) but got it all buttoned up on Saturday. I drove my son across town this morning and then headed up to work, so far the clutch works great with no added noise .
The ground issue didn't clear up the engine glitch however. I dropped my son off then stopped for gas, motor running strong and smooth. Left the station and it began to stumble, not able to get to 2000rpm's. Came to a 4 way stop, proceeded and the motor was back to normal :?. Stopped at a 7-11 when I took off it stumbled again, came to a red light.....you got it, when I took off it was back to strong and smooth mehh:?
Any ideas?.....thanks, Jim S.

 

good news, bad news, good news

still having an issue with the motor performance. I pulled some plugs and they're all REAL lean...........
1st good news, ........put a fuel pressure gauge on the fuel rail and drove around. Fuel pressure was betwwen 32lb and 40+ lbs, even when the motor was sputtering and back firing.........pump/system is fine
2nd bad news........unplugged the plug to the air meter on the intake with motor running made NO change to idle .....wiring/bad ground/ or bad computer (computer is not throwing codes)
3rd good news......without the air flow meter plugged in the Jeep runs like a scalded dog

Got to get in touch with the mechanic who did the Mass Air swap, he's been stand up to this point so I think he'll take care of me.....stay tuned
Jim S.