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Old 08-28-2014, 04:52 PM   #1
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Custom 95 YJ Stretch 5.0 Build

So I sold the 4 banger in my Jeep. Just got off the phone with the guy and were pulling it Sunday morning. 4banger with an AX15 conversion, np231 with an SYE and both driveshafts will be gone.

I am going to pull the body off the frame and stretch the frame about 15". I am then going to stretch the tub. I am going to do what Chop110 did. Been thinking about it ever since I saw his thread a while back.

Another TJ-6 Build

I am going to weld braces to both halves of the frame to make sure mine stays square though and I dont end up 1/2" off on one side in the rear.

I am then going to run a 2001 302 I already have with an NP435/NP205 combo I am still looking for. Getting rid of the 1310 CV Shaft I have and put in a non-cv 1350 or 1410 shaft. Havent decided yet. Going to do a port and polish on the upper and lower intake manifolds and exhaust manifolds. Still have not decided if I am going to run the exhaust manifolds that came on it or not since they are gt40p heads. Either way I will be making a custom single exhaust.

I have all the parts I need lined up and will be going on a shopping spree this next week with 100% of the cash from the sale. Will need to throw in a little more too. I am hoping with the stretch and short transmission to pull off a flat belly, but I will have to see what the angles look like first to avoid a cv shaft.

I will keep this thread up to date while I go along to try and repay all the threads that have helped me over the years. Expecting my Jeep to be off the road for 6 months since I will be putting in a custom cage as well. I was going to put coils up front too, but I cant fit them in the budget.
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__________________
Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 08-28-2014, 09:33 PM   #2
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Glad to see the project up and going, looking forward to progress, if you need anything like I sent you let me know and I'll give you whatever I have that you can use. Good luck with it.

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1993 YJ. 6" BDS 38's
2010 Rubicon 5.5 Rock Krawler coilover 38's
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Old 08-28-2014, 10:06 PM   #3
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Thanks man. I started tearing it apart tonight.
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Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 08-28-2014, 11:49 PM   #4
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Sounds like a plan!
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Old 08-29-2014, 01:46 PM   #5
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Pulled the front apart and un-wired some of it. I am keeping all the thick custom wires I have in there and my relays. Firewall is roached. Anyone knows what the best paint is? I would like something extremely high gloss. I know I will hear por15, but if I could go with a custom sound deadening and heat reducing option without breaking the bank I would do that instead. I know they make material you can glue to it or however you attach it, but the stuff I found would cost me a few hundred just for the firewall.

I am taking the tub off this weekend or next and will be doing the whole underneath properly as well. Think I will just stand the body on its side.
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__________________
Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 09-02-2014, 08:41 PM   #6
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For the front only. Long arm 4 link. Heim joint kit is $80 and then I just need to grab some thick DOM and start fabricating axle mounts and buckets. I am going to integrate the shock directly with the bucket in some way. So they move together. Not sure how yet. If anyone has link to anyone who has done this that would be cool. It doesn't make sense to make two separate mounts for the coils and shocks. These are 8.5"-9" lift springs for a tj or xj. I am going to mount the top buckets high similar to a Bronco. Take advantage of the extra length. Going to keep it as close to about 6.5-7" I am at now. Guy I got them from said they flex awesome, but he rolled his rig. Was pretty trashed. I should have taken a pic.
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__________________
Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 09-04-2014, 02:32 PM   #7
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Of all things to break. I noticed this thing leaking oil all over my tank from the cylinder crankcase gasket, so new gaskets are on the way. This controls my vehicle lift and air tools. It is a cast iron 1962 Quincy 310 2 stage compressor on an 80 gallon tank. Now my Jeep has to wait. It still runs, but is hot, and I am not damaging this.

And I just picked up my NP435 NP205 combo for the 302 the other day.
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__________________
Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 09-06-2014, 03:49 PM   #8
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Got the Astro box for the front stretch. I hooked up my drag link to it just so I could measure the angles I will get when I move the axle forward before cutting the front of the frame for coils. I am going to reinforce the interior of the frame with 3/16" angle iron with gussets in it. I am going to close it with 1/8" on the side, and probably put a 3/16" plate on the backside for extra strength, maybe 1/4".
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__________________
Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 01-19-2015, 10:45 AM   #9
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So things are finally coming along again. I had a couple of jobs come up that required my lift, but from here on out everyone knows my lift is out of commission until this Jeep DRIVES off of it.

I got my H1 37's. I have my XJ leaf springs painted and ready for assembly as soon as the new pads get here. I also got a can of good quality dry graphite lube for reassembly. They should break in nice and quick.

I was going to do a military wrap, but I decided against it. Biggest reason why is because I had awesome flex in the back with my previous SOA springs, and they were custom built for me by a spring shop. I am following their design, and using one less clip for some extra droop in the back.

I decided to build this, then decide from there on axle width, and might hit the trails a few times full width first. Only reason is legalities in my state prevent me from running full width axles in a wrangler without such heavy modification it would look ridiculous. I would technically have to widen the body which I contemplated for about a week before deciding against it. If I used flares I would not get pulled over, but they would look like frigging wings.

Any advice is appreciated. Especially if anyone has put a 302 in a YJ before using the advance Adapter mount kit. I have my placement of the mounts marked off, but have not set the height. I want it as low as possible, without my oil pan or exhaust hanging too low, and I do not want to have to lift the body higher than absolutely needed to fit my NP435 in there. I am also going to cut the tub for it as well if possible. Not sure If I should just sit the motor in the frame as low as I can while still accessing the spark plugs? It is tricky because I have to go a couple inches to the passenger side, and will have to cut up these motor mounts to get it to fit properly if I do that. the other alternative would be to weld the motor mounts level with the top of the frame. Then it comes down to body lift again, plus a higher center of gravity. Any advice here would be great.
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Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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Old 01-19-2015, 11:59 AM   #10
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I tried the Astro box and really did not like the forward facing pitman arm. I am currently using the Astro arm on a stock box, but am changing things a bit again and building a custom arm so I can use a rod end at the arm.

As far as engine placement goes, the best thing to do is assemble the whole drive train and hang it in place. I raised my engine until the tranny just cleared the tub with the drive train angled at 2 degrees. I used a screw type jack on the t-case so I could adjust the angle precisely.
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DaddyJeep build Thread:http://www.wranglerforum.com/f8/dadd...ld-122601.html
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Old 01-19-2015, 12:00 PM   #11
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the roughness inside the intake runners helps the gas to atomize before entering the combustion chambers,so you might not want to polish them..just match the ports where the intake meets the head..match the ports on the exhaust the same way and polish the exhaust..just my 2 cents
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Old 01-19-2015, 07:04 PM   #12
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Yeah. I am going to build 1/4"-3/8"armor to block the pitman arm from getting hung up on anything. I know exactly what you mean. I am also moving the bolt locations through the frame as far high and back as possible so the tip of the pitman arm is just behind and below the tube in the front of the frame. That will be fine for a 4" stretch. Only thing that makes it tricky is the radiator. Right now the radiator is off, but I am going to put that and the grill on for engine fitment before everything is final.

As for the intake runners and things. I must have mis-spoke, but I did not re-read what I typed. I was just talking about the exhaust headers. The stock ones are horrible. I am considering a pair of the tight fit huggers off eBay. They look like they flow quite a bit better for $120. The 302 I got is out of a 2001 Explorer and has the GT40P heads on it, so I am not messing with those since they will perform fine. Only engine work I am actually going to do besides changing out the crappy exhaust headers is clean up the lower intake so I get a little more CFM.

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Complete rebuild axle/engine/everything swap in progress:
Parts already gathered for assembly: 2001 Ford 302, 1990 Mustang GT 5.0 ECU and wiring, NP435, NP205, Pair of axles from 04' F350 SuperDuty (Sterling 10.5 Posi rear, Dana 60HP Front-Both Disk Brakes 3.73 Gears), 37" H1 Tires, 9" lift TJ Coils for 2 link conversion in front, Stage 2 Clutch Kit, 3 Row Aluminum Radiator, Chevy Astro Steering box (4" front Stretch), XJ Rear Leaf Springs (6" Rear Stretch), and lots more.
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