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Old 05-31-2009, 07:55 PM   #1
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Chassis ISSUE - builders, help!

Hey all -

Okay, so I am making really good headway on my chassis swap. Got just about EVERYTHING off the old chassis. Today, when I went to go mount the transmission support pan on the new chassis, the trans mount didn't line up with the holes in the support pan. I made sure the new pan matched the old, rotten one - perfectly fine. I started to panic... I've got the engine and trans cradled in the engine mounts. So I grab the short drive shaft (again, from the old chassis) going from the tranny to the rear. It's too long. Now I am totally freaking. I check the motor mounts on the new chassis as compared to the old one - - - There's my issue. The motor mounts on the new chassis are about four inches closer to the rear of the chassis than on the old chassis. Old chassis is a 1992 YJ, the new one I believe is from a 1996 YJ.

I've got a big issue. Did they change positions on the motor mounts for different size engines? Can I buy new mounts and weld them on the new chassis where they NEED to be?

Help guys - I am in panic mode right now. I am 6200 into this project, initial purchase included. HELP.

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Old 05-31-2009, 08:56 PM   #2
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The motor mounts on the new chassis are about four inches closer to the rear of the chassis than on the old chassis. Old chassis is a 1992 YJ, the new one I believe is from a 1996 YJ.

I've got a big issue. Did they change positions on the motor mounts for different size engines?
oops, sounds like a frame is different for 4+6 CYL engines. using the trans mount as a guide you can cut out mounts from old chasis and weld on new frame. really shouldnt be too hard, if you own a welder and can weld. before doing much more ide go with a tape measure and go around check all measurements. check all mounts distance and cross check. as far as which way to weld ide prefer to use a stick welder for something that thick and buy good 1/8" welding rods. im sure some will prefer mig but thats ok. do what your comfortable with.

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Old 05-31-2009, 09:02 PM   #3
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Well it cant really be a 1996 frame, as there was never any wranglers made that year.
The plants were re-tooling for the new TJ's.

I think your issue may be that the newer frame was for a 4 banger. I'm not positive of this, but they do sit much farther back in the engine bay.

You'll obviously want to move the mounts forward. I have never done this, but any good welding shop should be able to use the mounts from your previous frame & put them where they need to be on the new frame.

You may need to have both frames on hand, so a house call by a mobile welding service might be the better choice. Once you add in towing, on a flatbed, it will cheaper to do it where the jeep is now.
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Old 05-31-2009, 09:54 PM   #4
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nope, it can't be a 96 yj frame. and yes, the 6 cylinder motor mounts are further back than the 4 cyl motor mounts.
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Old 05-31-2009, 10:00 PM   #5
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nope, it can't be a 96 yj frame. and yes, the 4 cylinder motor mounts are further back than the 6 cyl motor mounts.
Fissed!
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Old 05-31-2009, 10:01 PM   #6
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Fissed!
dyslexia sucks
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Old 06-01-2009, 04:25 AM   #7
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dyslexia sucks
I know, I have it too!
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Old 06-01-2009, 06:30 AM   #8
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Okay, thanks guys. I've got a welder in the area, so I'll get him out here. In the meantime, I'll check different measurements around the frame to make sure this is the only thing that is differnet.

Thanks, as always, for the help. A good night's sleep and some answers to my questions has me feeling better about the chassis. I was really starting to make some good progress this weekend and then - SLAM - this comes along. Took the air outta my sails...

Thanks -
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Old 06-01-2009, 12:51 PM   #9
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one thing i notice about wranglers is really how beefy the frame is. ok, some have rotted but the ones like mine that are clean and rust free can probably be whacked with a sledge hammer without even leaving a mark. Welding would not be a problem.

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