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Trying to get it mostly right the first time: A 5.9 Magnum and 46RE swapped, Tummy Tucked Daily Driven Jeep TJ
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<blockquote data-quote="Dan_Goodwin" data-source="post: 763692" data-attributes="member: 4960"><p>At this point I've given up on deadlines and am simply putting in the hours until this is done. </p><p></p><p>With the 2.5 out, it was time to rinse and repeat and get the drivetrain set in its final home. A Sawzall, grinder and air hammer (sorry neighbors) removed the old engine mounts. I set the mounts to the same 5* angle back I'd mocked them up for, fully welded and painted them. </p><p></p><p>The engine refresh was completed, so I turned my attention to the transmission and transfer case. The transmission received a new Wix filter and pan gasket, new overdrive housing (I cracked the old one-oops), new torque converter (another oops – I scrapped the old one) and a sending unit mounted in the pan for the Glow Shift gauge. The pan in the 46RE had some clutch material and minor metal flake but not enough to concern me so I'll run this transmission until it needs a rebuild. </p><p></p><p>Next was to install the JB Conversions SSSYE. Since the AX-5 transmission that comes behind the 2.5L has a 21 spline input and the 46RE has a 23 spline input I needed to swap the input shaft. I bought a pair of lock ring pliers off Amazon <a href="https://www.hardlinecrawlers.com/#_msocom_1" target="_blank">[DG1]</a> and went to work. The only difference I found between the NP231D and NP231J was the output shaft and shaft housing, but since I'm swapping in a SYE that is now irrelevant. I opted to keep my Jeep case and swap everything into it. </p><p></p><p>[ATTACH=full]161450[/ATTACH]</p><p></p><p>There's really not much to the NP231, so installing the SYE was a matter of disassembling both cases, swapping parts around and reassembling. I'd read on other threads about folks buying and swapping in an HD chain, 6 gear planetary and input shaft and here is an advantage to buying a Dodge as a donor (not sure if this is applicable to a GC or not) – my Dodge NP231 already had 2 out of the 3 so there's no need to buy anything. </p><p></p><p>My NP231D had the same 3 pinion planetary, so no upgrade there. The input shaft was removed and installed into the Jeep case. </p><p></p><p>[ATTACH=full]161452[/ATTACH]</p><p></p><p>It did have the wider HD sprocket and chain:</p><p></p><p>[ATTACH=full]161451[/ATTACH]</p><p></p><p>This shows the differences in the input shafts. From Left to Right: JBC, NP231J and NP231D. Look how short the JBC SYE is!</p><p></p><p>[ATTACH=full]161453[/ATTACH]</p><p></p><p>I installed a thin bead of ultra grey RTV to the case halves, torqued everything to spec and bolted the transfer case back up to the transmission. </p><p></p><p><s>[ATTACH=full]161449[/ATTACH]</s></p><p></p><p>The transmission was married back to the engine and the entire assembly went into the Jeep for what should be the final time. </p><p></p><p>[ATTACH=full]161455[/ATTACH]</p><p>[ATTACH=full]161454[/ATTACH]</p></blockquote><p></p>
[QUOTE="Dan_Goodwin, post: 763692, member: 4960"] At this point I've given up on deadlines and am simply putting in the hours until this is done. With the 2.5 out, it was time to rinse and repeat and get the drivetrain set in its final home. A Sawzall, grinder and air hammer (sorry neighbors) removed the old engine mounts. I set the mounts to the same 5* angle back I'd mocked them up for, fully welded and painted them. The engine refresh was completed, so I turned my attention to the transmission and transfer case. The transmission received a new Wix filter and pan gasket, new overdrive housing (I cracked the old one-oops), new torque converter (another oops – I scrapped the old one) and a sending unit mounted in the pan for the Glow Shift gauge. The pan in the 46RE had some clutch material and minor metal flake but not enough to concern me so I'll run this transmission until it needs a rebuild. Next was to install the JB Conversions SSSYE. Since the AX-5 transmission that comes behind the 2.5L has a 21 spline input and the 46RE has a 23 spline input I needed to swap the input shaft. I bought a pair of lock ring pliers off Amazon [URL='https://www.hardlinecrawlers.com/#_msocom_1'][DG1][/URL] and went to work. The only difference I found between the NP231D and NP231J was the output shaft and shaft housing, but since I'm swapping in a SYE that is now irrelevant. I opted to keep my Jeep case and swap everything into it. [ATTACH type="full"]161450[/ATTACH] There's really not much to the NP231, so installing the SYE was a matter of disassembling both cases, swapping parts around and reassembling. I'd read on other threads about folks buying and swapping in an HD chain, 6 gear planetary and input shaft and here is an advantage to buying a Dodge as a donor (not sure if this is applicable to a GC or not) – my Dodge NP231 already had 2 out of the 3 so there's no need to buy anything. My NP231D had the same 3 pinion planetary, so no upgrade there. The input shaft was removed and installed into the Jeep case. [ATTACH type="full"]161452[/ATTACH] It did have the wider HD sprocket and chain: [ATTACH type="full"]161451[/ATTACH] This shows the differences in the input shafts. From Left to Right: JBC, NP231J and NP231D. Look how short the JBC SYE is! [ATTACH type="full"]161453[/ATTACH] I installed a thin bead of ultra grey RTV to the case halves, torqued everything to spec and bolted the transfer case back up to the transmission. [S][ATTACH type="full"]161449[/ATTACH][/S] The transmission was married back to the engine and the entire assembly went into the Jeep for what should be the final time. [ATTACH type="full"]161455[/ATTACH] [ATTACH type="full"]161454[/ATTACH] [/QUOTE]
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Trying to get it mostly right the first time: A 5.9 Magnum and 46RE swapped, Tummy Tucked Daily Driven Jeep TJ
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