Help with 4.0 install

snakester14

Active Member
Joined
Nov 3, 2006
Location
Greenville
I am currently in the middle of putting a fresh 4.0 in my 96 XJ and am having a little trouble. Me and a few buddys (who have never done anything like this before) got the engine lined up with the tranny output splines but couldn't get it the last 1/2 inch to bolt it up. It would be nice to have someone whos done this before help.

The main thing is the 4.0 is from an auto and I have a ax-15 in the Jeep. So I swaped the flywheel onto it, put a pilot sleeve and bearing in and put the inspection plate on.

I am in Cary NC btw

thanks,
Jake
 
When I put the T18a in my CJ-5, I had the same trouble. Pulled it out several times. Even got out the calipers and measured the pilot bushing and input shaft. Cussed it. cussed some more, pulled it out, measured again, stared at it a while, and on and on. Checked and rechecked with the alignment tool. Measured the alignment tool against the input shaft. This went on for a couple of hours of fighting it.

Decided to try it one more time. Slipped right in on the first try. Nothing had changed. Go figure.

Sorry this doesn't help much. But just check and recheck everything.
 
jph0913 said:
Isnt there a difference in the flywheel between the auto trans and the manual trans? something about the pilot bearing...
Click to expand...

Well the auto had a flexplate and manual had a flywheel so I swapped them.
 
tknopp said:
Just use longer bolts in the bellhousing. get them started and it should pull it flush with the block. Then swap out the longer bolts for the correct ones.
Click to expand...

Ok all try that, should I use the side block bolts or the top etrox ones?
thanks,
Jake
 
Question...the input shaft...is the tip of it cut off flat and straight, or are the edges chamfered? With 1/2 inch to go, you are most likely not hitting the hole...just a 1/32 off will jam you up. You can take a flap disk and break the leading edge a hair. Just go evenly all the way around...maybe a 1/16 chamfer or so.

On the bolt thing...snug it up, and 'wiggle' the trans, then snug up more....if you crank the bolts down, and the input shaft isn't dropping into the pilot bushing, you'll probably just deform one edge of the pilot bushing and that'll lock you out. Doesn't take much of a "dent" along the rim of the pilot bushing to jam you up.

Worst case, don't be a gorilla and force it by cranking down on the bolts...bust an ear and you've really screwed up.

You did set up he clutch with an alignment tool, right?
 
make sure the ID of the pilot bushing and the OD of the input shaft match.

You slipped the bearing over the input shaft before you put it in the block, right? Just to make sure you got the right one?

You used the correct alignment tool, it should have come with the clutch kit?

It should slide right in, if it is really hung up on that last half inch, I would make darn sure everything is sized properly before you ram it home. I have put a transmission or 20 behind 4.0/4.2 motors and have not had to force them much, if any at all.

If you are still having trouble tomorrow, PM me, i might be able to stop by after work (1930-2000ish)
 
You DO have a pilot bushing in the crankshaft, don't you?

Am I remembering right that some of the later 4.0's with an auto have a different crankshaft that doesn't even have the hole that a pilot bearing goes into? Or is that another motor?
 
gavan said:
make sure the ID of the pilot bushing and the OD of the input shaft match.
You slipped the bearing over the input shaft before you put it in the block, right? Just to make sure you got the right one?
You used the correct alignment tool, it should have come with the clutch kit?
It should slide right in, if it is really hung up on that last half inch, I would make darn sure everything is sized properly before you ram it home. I have put a transmission or 20 behind 4.0/4.2 motors and have not had to force them much, if any at all.
If you are still having trouble tomorrow, PM me, i might be able to stop by after work (1930-2000ish)
Click to expand...

I forgot to check the it by sliding it over the input shaft unfortunately. The ID of the bushing is .75 and the OD of the input shaft is .75
I have another .75 pilot bearing lying around and it slid right over so im thinking we may have damaged the other one a hair while putting it in.

And yes I did use the clutch alignment tool
PHP:

kaiser715 said:
You DO have a pilot bushing in the crankshaft, don't you?

Am I remembering right that some of the later 4.0's with an auto have a different crankshaft that doesn't even have the hole that a pilot bearing goes into? Or is that another motor?
Click to expand...

Yes I have a pilot bushing ing the crankshaft and I didn't know some of the autos had a different crankshaft but mine had a whole for a pilot sleeve and pilot bearing.
 
ai290.photobucket.com_albums_ll246_snakester14_EngineSwap057.jpg

ai290.photobucket.com_albums_ll246_snakester14_EngineSwap056.jpg
 
OK...that's good. Didn't mean to sound smart-ass or Captain Obvious or anything. I work in systems support. Yes, people have gotten pissed because I've asked on the phone if something is turned on, if the see the green lights, etc....then drive an hour to find out the printer is turned off. :) I've learned to ask the obvious.

I should be working in Raleigh tomorrow...I can stop by early afternoon if you want a hand figuring it out.
 
yager said:
along with the other suggestions, you might try putting it in gear and turning the output some.
Click to expand...

Thanks man I did that and we got the splines locked in but it wouldn't go that last half inch
 
I don't really have any good advice, but i will tell you from experience that if you use the bellhousing bolts to pull it together, you can very easily bust the bellhousing. VERY EASILY.

It may just need a lot wiggling to get everything lined up perfectly. If the crankshaft and the input-shaft aren't in perfect alignment, it won't go. It should fit really tight, but shouldn't require any force. When it gets lined up properly, it should pretty much slide together.
 
Just got back from the beach so im gonna mess with it tonight and report back.
 
Anyone feel like comin out and lendin a hand today For a case or somethin?
 
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