2004 Hand me down back to Dad TJ

[stlaser]

So thought I’d start a thread on my 2004 TJ Sport. It’s been driven by 2 daughters and had some various upgrades which I’ll try to cover. It’s a 2.4L 5spd manual sport Jeep with a well worn out motor with hardly any compression and some oil usage. My youngest is currently driving it until August when she heads to Bozeman with the middle daughter at MT ST.

I personally really like the TJ platform and had a 2004 Rubicon w/ 33’s for about 10 years in Indiana when girls were growing up. So I’ll be gutting this one for myself.

[stlaser]

Picked this up on a barter yesterday up in Torrington WY, it’s a 2.0 CR 2013 TDI w/ 67k original miles. This will be going into the TJ one way or another this fall. Should net around 30 mpg when completed.


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[stlaser]

August of 20

At this time lots of things were worn out and upgraded. The little motor needed help after the oldest put 32.8” tires and wheels on it. So I built an explorer 8.8 and rebuilt the limited slip and added 4.56 gears. We found a semi fresh Dana 30 front that had gears installed by 4 wheel parts for a couple hundred and added all new steering and brakes. Clutch was replaced prior by oldest daughter.

Plan is to swap motor, transmission (probably newer manual 6spd) and a better t-case. Get it running then address axle upgrade with tru lockers and slightly larger tires and beadlocks. Thinking selectable and 37’s with Dana 44 front and possibly keep the 8.8 rear or go to a full float 60 in the rear. I don’t really want a 60 in the rear but the full float is helpful if I bust a shaft at some point. Update the suspension and link it maybe? Or I might do a radius arm setup front and rear keeping coil springs. This would keep budget down and be relatively maintenance free versus coilovers. Gunna be my wheeling beater……..


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[oklawall]

Looking forward to watching this

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[Flyin6]

Picked this up on a barter yesterday up in Torrington WY, it’s a 2.0 CR 2013 TDI w/ 67k original miles. This will be going into the TJ one way or another this fall. Should net around 30 mpg when completed.


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No friggin way! That is tooooo kool!

[KensAuto]

As much as I despise VWs, I look forward to this project.

[TexasRedNeck]

Specs on that engine Shawn?


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[stlaser]

Specs on that engine Shawn?


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Company putting these into the next gen Jk & jku’s claim 180hp / 360tq, the tj is a much lighter chassis and this motor is around 100# lighter than the original 2.4L the low end torque makes it a great motor for the application. I’m currently trying to source an oem ecu & wire harness as that’s the cheapest way to tune it and get it running. Several companies make a stand alone but they’re proud of it.

[TexasRedNeck]

Oh wow.  Pretty decent tq.  That must be turned up a bit from factory?


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[stlaser]

Oh wow.  Pretty decent tq.  That must be turned up a bit from factory?


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I would guess that is correct, looking at egr deletes for it now.

[stlaser]

Got the motor up on a spare engine stand. Guy I acquired this from was a vw mechanic. His wife engine was giving him issues so he had pulled two of the injectors but included two nib Bosch units with it. First thing will be to turn the motor over and clean injector sockets then reinstall those and fuel lines.


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[TexasRedNeck]

A more civilized swap than the 4BT


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[stlaser]

A more civilized swap than the 4BT


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4bt is too heavy for this type of application, enough said really…..

[Bigdave_185]

So did I read that all correct? You are putting a turbo diesel from a Volkswagen into your jeep.
Lighter motor.
More torque.
Fuel economy probably(?)

You going to keep the same transmission?

Any gear reduction system like twin sticks for more torque?


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[stlaser]

So did I read that all correct? You are putting a turbo diesel from a Volkswagen into your jeep.
Lighter motor.
More torque.
Fuel economy probably(?)

You going to keep the same transmission?

Any gear reduction system like twin sticks for more torque?


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So probably not same transmission which is ok. The current clutch / fly wheel setup with the stock nv1550 transmission is expensive. I’ll most likely upgrade the trans to the nv3550 which is another Jeep 5spd but good for 300+ hp. The nv1550 no one makes an adapter from the 2.0 cr to that transmission. Several companies do for the nv3550 to 2.0 cr & as far as T-case most likely an np205 with a range reduction box in front of it but that will be down the road once I get it running with these axles and t-case.

[EL TATE]

Pretty cool Shawn! Check your manifolds; I've seen one that was so blocked up with carbon deposits you could hardly fit a finger in there.

[Flyin6]

I see an EGR cooler

Get rid of all that tree hugger crap for sure

[stlaser]

I see an EGR cooler

Get rid of all that tree hugger crap for sure

Pretty cool Shawn! Check your manifolds; I've seen one that was so blocked up with carbon deposits you could hardly fit a finger in there.

EGR delete is $200, think I found an 04-06 tj 6 speed but it needs rebuilt. Tate, you have a kit for that? Get me a quote …..

I’m hoping someone makes a better manifold and a slightly larger turbo to bolt on this. Still researching…..

[EL TATE]

email sent Shawn

[stlaser]

email sent Shawn

Got it, thank you. Trying to lock down this transmission now.

After a bit more research the fuel pump upgrade for this is a Bosch CP3 unit. Better save up my lunch money as they don’t give those away!

[KensAuto]

I would be sure to run VW spec oil in that thing. Might wanna look over the valve train also. Him being a tech hopefully means he used the right oil, but never know.

[stlaser]

So yesterday was axle tear down day, because I cleaned the shop end of last week spotless and well you just can’t have a clean axle shop ask Tate!

In the pictures is what’s left of a early to mid 70’s high pinion 44 drum brake housing. I had picked this up cheap a couple years ago as it’s a great housing that is easily trussed for the front of the tj as the radius arm c’s are easily removed versus some of the casted c’s which are not so easy to upgrade. To build this out the way I wanted I also tore down a gm 44 with flat top knuckles which I’ll use in conjunction with this axle to get 8 lug and high steer setup.

I’ve ordered a Jana 54 kit from Jantz Engineering which allows you to install a Dana 50 R&P into this housing after some massaging & increasing the R&P strength around 40%. I have on order an Eaton e locker from Tate for this as well. Plan is to go chromoly shafts and it should be an extremely strong front axle. I’m planning on building a GLO Dana 44 cover with load bolts too.

I am at a dilemma or crossroads on a couple points. First is coil overs or keep the coil springs. Second is using a radius arm setup or do a truss and use a 3 link setup. Last is the rear axle, I’m leaning towards a 14 bolt and trim the bottom of housing to use a 13 bolt cover.


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[TexasRedNeck]

The mulch at the mall won’t care….


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[Bigdave_185]

For an unlearned guy
Walk though the pros of each set up and maybe the process will help you pick and us learn a thang or two


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[stlaser]

For an unlearned guy
Walk though the pros of each set up and maybe the process will help you pick and us learn a thang or two


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Coilover, infinitely adjustable to control suspension. Downside is maintenance. Coil spring, not near as adjustable but you can punt it off a 14k Colorado mountain peak and not hurt it. No maintenance really.

Radius arm, probably not as much articulation (flex) however very stable and predictable. Simple stupid to set up. 3 link more flex but depending on suspension maybe not as stable (lots of variables in the setup). Definitely more work to get it “right” or as close to it as you can because I’ll still be limited to some extent to the oem chassis or what’s left and used.

Rear axle, I want a full float 8 lug rear. Several options, Dana 60 but not near as strong and 30 spline shafts. 14 bolt, pure beef 31 spline shafts. Both are equal in pricing for parts really. Ground clearance can be made the same by cutting bottom of 14 bolt and running my 13 bolt cover.

I’ve also located a cab n chassis 14 bolt which is 63” wms, front 44 should be around 64-65” wms. Although I have a rear ford 60 on the shelf too which is bought and paid for. I have gears and install kit for 60 but not for 14 bolt.

[stlaser]

The mulch at the mall won’t care….


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Very good point, since it won’t be seeing the mall or the mulch beds!

[Flyin6]

The mulch at the mall won’t care….


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Very good point, since it won’t be seeing the mall or the mulch beds!

Good!

If you want this thing to live stay out of the mulch!

[JR]

Links and coil overs I say, but who am I.

I had a Samurai wish I had kept and eye'd a TDI for it. Brings but memories,,,,,,

[stlaser]

Well, 3 link coil overs and custom truss has won out. I knocked the radius arm mounts and track bar bracket off along with a lot of rust and dust. Taking this housing, a set of gm 8 lug disc knuckles and backing plates to sand blaster in the morning.

Tnt customs wanted just shy of $700 for their truss. I already have several lengths of 1 5/8 HR tube bought and paid for. I’ll bend up & fabricate my own truss for this housing.

Not sure if I mentioned it but this Dana 44 housing also has the 1/2” thick tubes which is a major bonus.




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[JR]

Do the gm 10 bolt and the 44 share the same specs? I have heard the 10 bolt has a little stoughter pinion, but you can get more parts for the 44.

So a 44 flattop knuckle would go on the 10b?

[Bigdave_185]

Looking forward to seeing her all finished up


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[stlaser]

Do the gm 10 bolt and the 44 share the same specs? I have heard the 10 bolt has a little stoughter pinion, but you can get more parts for the 44.

So a 44 flattop knuckle would go on the 10b?

D44 has larger carrier bearings and 30 spline inner shafts versus 10 bolt that has 28 spline and smaller carrier bearings. Guys claim the 10 bolt pinion is stronger however it’s not stronger than a Dana 50…..

44 & 10 bolt c’s out are interchangeable yes.

[stlaser]

Looking forward to seeing her all finished up


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Me too, trying to buy parts is a slow progress though it seems.

[Bigdave_185]

What’s the word on the fummins?


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[stlaser]

What’s the word on the fummins?


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In one word SLOW……..

Shop I’m dealing with lost two mechanics as of late this year. I’m friends with owners, they owe me money. So it’s supposed to be back in the shop now finally getting a shorter list completed. Then I’ll get it back to finish soon I hope. Is what it is, not happy but biting my tongue currently.

[Bigdave_185]

That’s a tough spot, best of luck with your tongue and breaking even on the trade work.  I have always hated that.

Just last week a buddy called asking “if I knew anyone who hung cabinets” of course he knows I can/do so I’m obligated to either propose a trade or just agree to do the job for free.  I chose free and will let it go as a friend doing a friend a solid instead of trying to figure out $ into the deal


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[stlaser]

The other part of it is they assembled motor and they have the rebuilt injection pump. I’m wanting them to get cam broke in as “it’s their baby” so to speak…..

[stlaser]

So this 2 x 6” nib psc double ended ram showed up on marketplace last night for $100 and I snagged it this morning. These go for over $300 retail.

The Jana 54 kit arrived yesterday and after talking with Tate this morning I ordered the front e locker from Summit at full retail.

Housing, knuckles and brake backing plates are supposed to be ready at blaster late this week. Pretty busy at shop for next three weeks with a motorbike trip squished in the middle so probably won’t get time to start modifying the housing for the Dana 50 R&P until mid next month.

Also trying to locate a set of 8 lug hubs internally splined at a reasonable price but so far nothing.

I believe I found a 14 bolt rear axle out of a cab n chassis truck to use on the rear. I’m contemplating rear steer even with a mechanical lock for street driving…….


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[Bigdave_185]

How would the rear steer with mechanic lock work for an alignment?


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[JR]

Nice score on the ram.

[stlaser]

How would the rear steer with mechanic lock work for an alignment?


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Lol, honestly Dave I haven’t had an alignment done on a real truck in 30 years……..

Note: real truck means non ifs bs, I ain’t talking cars with truck bodies…. 

However, I’m thinking of an adjustable tie rod that will lock the steering to the axle tube. This way I can adjust it slightly if needed so it’s not dog tracking on the road.

[JR]

Heck, just getting an alignment is a chore now. 2 weeks out so hope I am close on the dmax.

Toe is easy.

[stlaser]

Sold the Jeep to a couple Guatemalan’s a few minutes ago. I had already sold the tdi anticipating I would sell this Jeep. Too many projects and going to be taking on a land development project up north shortly so it was time to cut ties. First time since 2006 I haven’t owned at least one running Jeep, end of an era.

[Bigdave_185]

Sold the Jeep to a couple Guatemalan’s a few minutes ago. I had already sold the tdi anticipating I would sell this Jeep. Too many projects and going to be taking on a land development project up north shortly so it was time to cut ties. First time since 2006 I haven’t owned at least one running Jeep, end of an era.

What happened to the Cummins swap flat bed? 


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[stlaser]

Sold the Jeep to a couple Guatemalan’s a few minutes ago. I had already sold the tdi anticipating I would sell this Jeep. Too many projects and going to be taking on a land development project up north shortly so it was time to cut ties. First time since 2006 I haven’t owned at least one running Jeep, end of an era.

What happened to the Cummins swap flat bed? 


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Still have it, it’s sitting in a bay at twin peaks diesel. I think we’re about ready to drop the cab down for the last time. I’ve built some piping for the compounds and we’ve figured out the oil drains. I purchased a mishimoto intercooler to handle the boost recently and started fabricating the down pipe.  Afc live is installed as are the 4k gov springs and no fuel plate. Timing is set at 19, need to get cab down and figure out coolant lines.

The current consensus is had I stayed with a single turbo this would have been done a couple months ago by now.

[wyorunner]

Sold the Jeep to a couple Guatemalan’s a few minutes ago. I had already sold the tdi anticipating I would sell this Jeep. Too many projects and going to be taking on a land development project up north shortly so it was time to cut ties. First time since 2006 I haven’t owned at least one running Jeep, end of an era.

What happened to the Cummins swap flat bed? 


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Still have it, it’s sitting in a bay at twin peaks diesel. I think we’re about ready to drop the cab down for the last time. I’ve built some piping for the compounds and we’ve figured out the oil drains. I purchased a mishimoto intercooler to handle the boost recently and started fabricating the down pipe.  Afc live is installed as are the 4k gov springs and no fuel plate. Timing is set at 19, need to get cab down and figure out coolant lines.

The current consensus is had I stayed with a single turbo this would have been done a couple months ago by now.

Two things, after reading the whole diesel keep thing I was like perfect, I need this as we have a 99 2wd 4runner needing to be 4wd and diesel. Then you kicked it out! Dang it!!!

Cummins, I’ll trade you my single for your compound. It’s an upgraded s300g from diesel tuff, aimed at keeping EGTs down under towing load.

Figured I’d help you atleast make your fummins on the road.

[stlaser]

Turner, always trying to be helpful. However I’m knee deep and I lost the bottom to my wallet on this project a long time ago so I’ll keep the compounds.

Interesting fact, I have a good customer who has a similar Jeep. He brought me a set of tons to build for him a few weeks ago. At the time I knew I needed to cut back on projects and long term I want to build a couple Jeeps but older versions my way. Anyhow he was talking of LS swapping his tj and well, I sold him lots of stuff. The tdi is a great conversion and if you need help hit me up as I have a lot of useful info on it.

[wyorunner]

Turner, always trying to be helpful. However I’m knee deep and I lost the bottom to my wallet on this project a long time ago so I’ll keep the compounds.

Interesting fact, I have a good customer who has a similar Jeep. He brought me a set of tons to build for him a few weeks ago. At the time I knew I needed to cut back on projects and long term I want to build a couple Jeeps but older versions my way. Anyhow he was talking of LS swapping his tj and well, I sold him lots of stuff. The tdi is a great conversion and if you need help hit me up as I have a lot of useful info on it.

Thank you sir!