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Old 12-04-2012, 11:12 AM   #1
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Cummins 4BT YJ Build!

Hey guys, I know there is always talk and controversy over the 4BT YJ engine swap, so I figured I would post my build up here.

The basics:

This was for my senior project to graduate with my BS in Mechanical Engineering Technology from Penn State.

I started with an 89 YJ I bought with no driveline, almost new interior, but ugly faded canary yellow paint.

I drove to Ohio and bought a 4BTA that was in a bread truck, It came with the alternator, power steering pump, turbo, aftercooler and some other junk.

I bought an NV 4500 5 spd, adapter, clutch, flywheel, master/slave, bellhousing, from a dodge ram 2500 that had a 12v cummins.

I got an adapter kit to mate the jeep NP 231 to the NV 4500

Got to work....

These are pics right after I loaded everything up from my house to take down to the school shop. I built this Jeep in the Penn State Harrisburg campus Engineering shop.
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Old 12-04-2012, 11:17 AM   #2
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With the driveline already removed, I bolted the engine and trans together and lowered it in to start designing some engine mounts.

And yes, the NV4500 is 2wd in this Pic, I converted it to 4wd and adapted it to the NP 231. Pics on that will come.
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Old 12-04-2012, 11:21 AM   #3
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Then I had a minor setback..... this is why welding safety is so important. I learned my lesson, never walk away from something you were just welding on.
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Old 12-04-2012, 11:29 AM   #4
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gunna be following this
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Old 12-04-2012, 11:52 AM   #5
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These pics are mostly rebuilding the trans and assembling the driveline, i am missing a few of setting up the clutch and mounting the T-case unfortunatley.
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Old 12-04-2012, 11:55 AM   #6
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More of the trans, wish I could find the rest of the pictures. O well, I basically had to replace the main shaft, bolt on the new adapter, and the T-cas bolted right on.

The NV 4500 is super easy to pull apart and re-build with instructions. I bought a total re-build manual.
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Old 12-04-2012, 12:00 PM   #7
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So with the body of my Jeep torched, luckily I got a deal on a sahara body, it was a bit of an uneasy 3 hour drive back though....
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Old 12-04-2012, 12:03 PM   #8
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With the new body on the Jeep and the shop fixed, I had all of 6 weeks to get this thing running!!

I mocked up some foam motor mounts til I was happy with the design

Then I just started mounting everything. I am sooooo glad I found this intercooler, it fits perfect
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Old 12-04-2012, 12:10 PM   #9
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I got the motor mounts laser cut and bent, then welded them myself.

Then just some paint and I bolted them on
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Old 12-04-2012, 12:11 PM   #10
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Then fininished welding them to the frame, with a fire extinguisher in hand this time.
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Old 12-04-2012, 12:12 PM   #11
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I will get more pics up tomorrow, but I just have to put the finished one up and a start up video.
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Old 12-04-2012, 12:18 PM   #12
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Old 12-04-2012, 12:20 PM   #13
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Old 12-04-2012, 12:57 PM   #14
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did you have a thread about this earlier? i think i remember seeing a thread a lot like this a couple weeks ago.
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Old 12-04-2012, 01:55 PM   #15
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Nice work! I gotta say I'm a bit jealous, I can't do anything like a 4BT since we have emissions testing where I live.
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Old 12-04-2012, 02:40 PM   #16
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This is an excellent build. Just be thankful only the Jeep body got torched. I've seen garages go up quick with similar situations.

I'm very jealous of your cummins.

Denis
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1991 YJ 99 Vortec 5.7L, SM465, NP205, 14 Bolt Rear, Dana 60 Front, 5.13 Gears, Detroit Lockers, 395/85R20 46" Michelin XML tires on 20" XD Wheels, Cherokee Offset Springs (10" front to back stretch total), Bilstein 5150s, 1in. BL, custom cage, Warn M8000, Double D Dash/OHC, 4Low Front Stinger Bumper, DirtWorx Rear Bumper WTC, Tube Fenders, Comp Cut, 1 Ton HD Kingpin High Steering and PAID FOR.
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Old 12-04-2012, 02:58 PM   #17
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Quote:
Originally Posted by RedSoCalYJ View Post
did you have a thread about this earlier? i think i remember seeing a thread a lot like this a couple weeks ago.

I have a thread on JeepForum.com as well, I dug up these pictures and figured I would make a new thread on here as well.

I hear so much controversy and assumptions over this swap that it drives me crazy.

Bottom line, it fits, its not too heavy, its not too loud, and its way more fun then the 4 other V8 Jeeps I have built and drove, but that might be cus I love hearing a turbo psssst every time I shift haha.

Low end torque is amazing, and fuel economy is great.

The swap is also quite a bit more expensive than a V8 swap though.

Also, I am selling the motor mounts I designed, PM me if interested.
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Old 12-04-2012, 03:12 PM   #18
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Originally Posted by youngjeeper11 View Post
The swap is also quite a bit more expensive than a V8 swap though.
Do you have figures on how much the swap cost you in time and materials? Would love to see a breakdown of the costs for the parts and how much time you spent so I know what I'd be getting into if I decided to go diesel over my original plan of going V8 gas.

Denis
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1991 YJ 99 Vortec 5.7L, SM465, NP205, 14 Bolt Rear, Dana 60 Front, 5.13 Gears, Detroit Lockers, 395/85R20 46" Michelin XML tires on 20" XD Wheels, Cherokee Offset Springs (10" front to back stretch total), Bilstein 5150s, 1in. BL, custom cage, Warn M8000, Double D Dash/OHC, 4Low Front Stinger Bumper, DirtWorx Rear Bumper WTC, Tube Fenders, Comp Cut, 1 Ton HD Kingpin High Steering and PAID FOR.
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Old 12-04-2012, 05:21 PM   #19
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Quote:
Originally Posted by denisbaldwin View Post
This is an excellent build. Just be thankful only the Jeep body got torched. I've seen garages go up quick with similar situations.

I'm very jealous of your cummins.

Denis
x2 I just had to clean drool off my keyboard....
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Old 12-04-2012, 06:22 PM   #20
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is it in a specific brand of bread truck we should look or just take a guest a try?
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Old 12-04-2012, 07:52 PM   #21
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Placement of my trans (before it caught on fire)

Sorry I am trying to put these pictures in some sort of order
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Old 12-04-2012, 08:17 PM   #22
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This build rocks.
Good work dude!!!
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94 YJ Black/Tan 4.0L 5Spd
4" RC - .5" Boom's - 1" BL - 15x8 Pro Comps - 33x10.5 GRABBERS - TJ Fr. Axles - RR CAI - RC Stabilizer - Bunch of other goodies!
My build:
http://www.wranglerforum.com/f8/my-9...vy-217965.html
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Old 12-04-2012, 08:20 PM   #23
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Sorry guys, I have been sitting in Starbucks trying to upload more pictures and it is just not working...


Quote:
Originally Posted by denisbaldwin View Post
Do you have figures on how much the swap cost you in time and materials? Would love to see a breakdown of the costs for the parts and how much time you spent so I know what I'd be getting into if I decided to go diesel over my original plan of going V8 gas.

Denis
The BIGGEST difference between a 4BT swap and a V8 swap is the cost of the engine. A Running 4BT with all the accessories on it from a bread truck (which is your best option, as it is already set up "automotive" style with an alternator, power steering pump ect) is really hard to find for under $2500, and you can find Chevy 350s everywhere.

Alot of people buy a whole bread truck, then cut apart the aluminum body and sell it for scrap to offset some costs.

Your next expense over a V8 is you will almost need at least 3" in overall lift, whether it be body lift or suspension. You can probably squeeze it with out lift, but it just makes it a lot easier to fit.

Other than that, the cost depends on your choice of trans, t-case, ect, so it is hard to give you a definite price, every project is different, every person desires something different, but the cost of a 4BT is almost always a lot more than any V8.

I got a deal and found someone parting out a 98 dodge ram 2500 cummins, I took the NV4500, adapter plate, bellhousing, flywheel, clutch, master/slave cylinder and a few other random parts for $1400. This all bolts directly to the 4BT! I feel this is easiest, strongest and most reliable set up you can do on the 4BT, not to mention the NV4500 has overdrive, and is arguably one of the best manual transmissions ever made, what more could you want?

Trying to mismatch bellhousings/transmissions/pilot bearings/clutches and searching for custom expensive adapters seems quite ridiculous to me. Just find a wrecked dodge ram cummins and you can salvage 80% of the driveline parts you need, you can even salvage the AC compressor if you want.

Of course, if you insist on an automatic (where is the fun in that) then that is a different story.

There were both Ford and Chevy bread trucks that came with 4BTs, the Chevy one is called a "P30" sometimes, not sure about the ford.
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Old 12-04-2012, 08:35 PM   #24
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I really wish I was you right now
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Old 12-04-2012, 08:41 PM   #25
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Quote:
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I really wish I was you right now

I really wish I had it driving right now, all these pics are from about a year ago when I was living in PA. Since I only had 6 weeks to build it, I cut a lot of corners, but I drove it to Virginia Beach, and tore it all back apart haha, i just got it started again for the first time in a few months last sunday, Soooo I am getting to those pictures.... if this internet would work
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Jeep 1: 93 YJ, TBI Chevy 350, SM 465, NP 231 SS SYE, 3.5" BDS, 33" BFG AT, 0 rust. Sold due to College.... Jeep2: 91 YJ, 4BT Cummins TD, NV4500, NP 231 SS SYE, 2.5" OME, many mods in progress. DD: 2001 Cummins 24v ext. Cab short bed, NV4500 5spd.

ASK ME ABOUT MY CUMMINS 4BT MOTOR MOUNTS!!!
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Old 12-04-2012, 08:42 PM   #26
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Is the Jeep finished and on the road?
Would love to see more pics!
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94 YJ Black/Tan 4.0L 5Spd
4" RC - .5" Boom's - 1" BL - 15x8 Pro Comps - 33x10.5 GRABBERS - TJ Fr. Axles - RR CAI - RC Stabilizer - Bunch of other goodies!
My build:
http://www.wranglerforum.com/f8/my-9...vy-217965.html
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Old 12-04-2012, 08:56 PM   #27
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It was, I drove it a total of about 500 miles, but, I hated my rigged wiring, and I decided to install an XJ HVAC system in it, so I tore it all apart to re-do everything

I am in the process of completely modifiying a wiring harness from a FI 95 YJ to work how I want it, and also adding dual power distribution centers to have all the fuses/relays I could ever want to run accessories, and designing a new sheetmetal dashboard......So it is not on the road right now.
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Jeep 1: 93 YJ, TBI Chevy 350, SM 465, NP 231 SS SYE, 3.5" BDS, 33" BFG AT, 0 rust. Sold due to College.... Jeep2: 91 YJ, 4BT Cummins TD, NV4500, NP 231 SS SYE, 2.5" OME, many mods in progress. DD: 2001 Cummins 24v ext. Cab short bed, NV4500 5spd.

ASK ME ABOUT MY CUMMINS 4BT MOTOR MOUNTS!!!
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Old 12-04-2012, 09:46 PM   #28
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Quote:
Originally Posted by youngjeeper11
It was, I drove it a total of about 500 miles, but, I hated my rigged wiring, and I decided to install an XJ HVAC system in it, so I tore it all apart to re-do everything

I am in the process of completely modifiying a wiring harness from a FI 95 YJ to work how I want it, and also adding dual power distribution centers to have all the fuses/relays I could ever want to run accessories, and designing a new sheetmetal dashboard......So it is not on the road right now.
Defiantly post some cad of the dashboard. I loved the custom motor mounts!
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Old 12-05-2012, 12:28 AM   #29
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Great build love the custom work
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Old 12-05-2012, 06:30 AM   #30
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Defiantly post some cad of the dashboard. I loved the custom motor mounts!
No prob, these were rendered a while ago when it was still conceptual, but you get the idea
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Jeep 1: 93 YJ, TBI Chevy 350, SM 465, NP 231 SS SYE, 3.5" BDS, 33" BFG AT, 0 rust. Sold due to College.... Jeep2: 91 YJ, 4BT Cummins TD, NV4500, NP 231 SS SYE, 2.5" OME, many mods in progress. DD: 2001 Cummins 24v ext. Cab short bed, NV4500 5spd.

ASK ME ABOUT MY CUMMINS 4BT MOTOR MOUNTS!!!
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