Engine/Tranny re-install

After the main pieces of the engine were assembled, we painted the block, head and oil pan. Then we installed many of the other components, such as water pump, thermostat, engine mounts, valve cover, ignition coil, intake and exhaust manifolds etc. With the engine assembled we removed it from the engine stand, installed the rear main bearing seal, flywheel and new clutch. We then attached the freshly rebuilt transmission, and dropped it in the Jeep. We are in the process of connecting the various wires, hoses, distributor, clamps, to the engine/tranny combo. Then we have the transfer case to install, a few driveshafts, linkages, new radiator and we should be ready to see if it starts. :-) In the process of installing the accessories I pulled out the alternator from a box only to find it had seized up solid. So......another new part and away we go.

Engine Assembly - Part 2

Here are a few more shots of the engine assembly...........

Engine Assembly - Part 1

After 5 weeks we finally got the engine parts back from the machine shop. They bored the block 0.020" over, cleaned the block, polished the crank, rebuilt the cylinder head, replaced the cam bearings, resized the connecting rod journals and installed the new pistons. They also sourced all the parts we needed for the rebuild: gasket set, bearings, rings, oil pump, lifters, timing chain and gears. See photo.

Step one was to install the crank bearings, and crankshaft, then plastigage the bearings to check for clearance. The clearance for all the main bearings was 0.002" - perfect. Once the crank was in, we checked the ring end gap and side clearance, then installed them on the pistons. With the rod bearings in the rods, we aligned the end gaps of the rings and installed the pistons. Jason did a great job of installing the pistons. Then went in the camshaft, timing gears and chain and timing cover. Next was oil pump and oil pan. Today we will work on the cylinder head, lifters, push rods, and rocker arms.

Tranny work

We disassembled the transmission a few weeks ago in order to replace the syncro's, bearings and seals. Upon disassembly we found the reverse gear and the reverse idler gear had some wear and so I ordered new gears (~$400 for the pair). We took a day to remove the input, output and counter shafts. Then used the new press to remove the gears and syncros from the shafts. The parts are held in with small metal circlips. In the process of disassembly we bent 3 of the circlips. I thought .. no problem I'll just go to the Jeep dealership and order them, they should only be a few dollars each. Well, at the dealership I was informed that Jeep no longer carries those clips. I couldn't believe it. For a 13 year old vehicle, you can get all the large tranny parts, but not the tiny clips that are critical to hold it together. I went to Just Jeeps and they said they could get one of the clips, but the most severely damaged clip was showing as no longer available to them as well. They ended up ordering both just on the chance they could get them, and both came in. Hurray. The last clip I rebent and feel pretty good it will hold. The tranny is still disassembled, but we hope to replace the clips and assemble to day. Here are a few photos......