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The_Dealers Build Thread


Got the flywheel, clutch, master cyl, lines, pilot bearing, and the trans in place. i also got the floor plate on. so now im waiting on my block plate and and ill be ready to slide the trans forward and start putting everything back together. i was a little worried about using the 91 master cyl, but from the looks of it i wont have any problems. man the pre bled master and slave with the line attached to the master was a pain in the ass to figure out how to run it. im not 100% positive its routed right, but i guess ill find out when i put the trans in. looks a little too close to the exhaust mani, but o well at least it has a burn sleeve
 
Im not exactly sure of the correct routing of the hose for the 91. I know when I did the 4 liter swap and m5od the hose ran in between the frame and the engine. Well a day after the thing was on the road it got against the exhaust pipe and burned through even with that burn sleeve. Pay attention to that really close as it cost me another line for not really paying attention. I went and got the line from the original 88 2.9 setup and when putting it in noticed it ran different. It was bent from the factory to run straight down(for the most part) from the master down under the floorboard and then up over the frame and straight into the trans. Much better way to rout it if you can get yours to go that way.
 
mines wierd it loops down like its about to run under the frame, then comes back up and goes over it, then straight to the trans. dont really know the purpose of that. my line is the same part number as the 88, so hopefully i wont have any issues. ill cut a slit down a section of fuel line and zip tie it to the line in addition to the burn sleeve if i have to
 
Well i got my block plate today, i got the trans in place and the lines for the clutch hooked up. all thats left is to get longer bellhousing to motor bolts some trans fluid and some break fluid to bleed the clutch, xmember and driveshafts. lol sounds like a lot but not really all that bad. will have some pics up tomorrow
 
x-member and driveshafts? I thought the trannys were the same length? I guess that is what I get for assuming huh?
Paul
 
they were the same length, i just have to put them back into place lol. tired from working 12 hours and messing with that for about 3...man i was thinking it wasnt going to be much to putting it all together. boy was i wrong couldnt get the starter part of the bellhousing past the y pipe. looks like i dont have the factory y pipe on it.

tried to get some pics of progress, but the gf was working the camera so pretty much she got pics of me cussing the floorjack for the wheel falling off and the cup thingy clip breaking:icon_rofl:

IMG00077-20110106-1927.jpg

IMG00081-20110106-1929.jpg


other then me trying to get the clutch spline lined up, which was my fault, everything was smooth. my dumbass wasnt thinking that the shifter wasnt in and i was turning the output shaft to line up the splines and the front wasnt moving...put the shifter in, put it in gear, and in she slid.
 
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Well i just finished up, and still no pics yet the batteries died in the camera. only problem i see is the shift lever hits the transmission and wont easily go into gear, without loosening the bracket. its not the "gate" pattern bracket, its the bottom of the lever right below the mounting bracket. i might can grind some off and make it work but im not sure i didnt notice it until i went to drive it and the t-case was in 4lo and wouldnt go into high until i loosened up the bracket some. is there a different shift linkage between the a4ld and fm146? also need to get my shift boot(be getting that from a member this week) i had to shove a rag around the t-case shifter to keep air from comming in. other then that everything is all good and i love it!!!! way lower gearing then the a4ld and i have no problem pulling hills at 70 in 5th lol. im satisfied. overall a pretty simple swap, and it didnt take but about 10 minutes to bleed the clutch
 
Alright, well for an update, I fixed the t-case linkage issue, i had to grind a little lip off of my t-case lever, and i used a washers made out of plate, cut the same pattern of the tcase lever bracket. So now i can use 4wd. Also took an old m5od boot and cut the bottom to put it over my shift lever until my new boot comes in. Getting some batteries tomorrow for the camera so i can get some pics. Trans is doing great, i still need to check the bellhousing to engine bolts to make sure they havent backed up any. Best part of all is i dont get the diesel rattle i was getting with the a4ld and cracked spacer.

So ive been trying to figure out what im gonna do next and i have a list

1)Im gonna remove the light bar and cheapo lights, and mount the lights under the rig as rock lights.
2)Ditching the push bar/grill guard, and about to start on a bumper, gonna cut the bottom of the fenders off flush with the front plate under the grill.
3)I need some poly body bushings really bad, so i think thats gonna be next, gonna do a 1" body lift while im at it.
4)Gonna drop the coil buckets about 1.25" and cut 1 turn off of my superlift xj coils(to stiffen em up some, and im gonna keep my spacers, but cut them in half. my goal is 5" with 2.5" pivot drops, RA drops, and camber bushings. if it dont work Ill get some skyjacker 4" pivots. already saving for some 35's and wheels

I'll be doing alot of free shit this week, as i just spent about $570 in total on the 5spd swap(thats with a free trans!!), and being sick last week had my check looking a little skinny. Ill be taking alot of pics or some of the stuff i need to tie up, gonna clean up alot of underhood wiring as well. Thinking about black indoor-outdoor carpet over my carpet, esp since i had to butcher it up to get the new floor plate in
 
Hey man, since you are ditchin the push bar would you sell it? I only wonder if it would fit right on a first gen bumper? My wifes would look good with that on it if it would fit her first gen bumper.
Paul
 
Hey man, since you are ditchin the push bar would you sell it? I only wonder if it would fit right on a first gen bumper? My wifes would look good with that on it if it would fit her first gen bumper.
Paul

his is a 1st gen...???? i just sold one for to cheap... should have sold it on here for more.. lol. oh well. i'm trying to sell my fabtech bar now.. anyways..

what you got planned on the bumper? something like what i'm doing? i'm so excited mine is almost finished... i wanna go get it now! lol i'm to ADD to wait :yahoo::yahoo::yahoo::yahoo::yahoo:
 
Well i snapped a pic of the 5spd swap, still need my new shift boots
swap.jpg



and we finally got some snow
snow.jpg



im bout to go wheeling, and shoot some pics
 

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