NV4500, Atlas II & Flat Skid in a TJ

3Sight

New Member
Joined
Jun 28, 2006
Location
Raleigh, NC
Well, I'm most of the way through fitting my NV4500, an Atlas II under the frame rails so I can add a flat skid plate. I'm building the skid from 1/4 plate with angle on the edges.
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I first tried an old bar from a high lift as my cross member, but it bend as soon as I installed it so I scraped it all and started over. I also was getting binding on the rear drive shaft so I added adjustable control arms on the rear.
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As I adjusted the pinion on the D44 the shocks hit, so I created new shock mounts out of the 2x2 square tube I bought for the new cross mount.
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I made mounts for the cross member out of extra 4x4 tube I had.
I got the crossmember in. Each side has 2, 1/4 bolts (grade 5). I drilled 3 holes in the mounts, but 2 seems pretty good right now. I might weld the edges as well, but not sure I need to do it. The cross member has 3" poly mounts welded to each end with 1/4 grade 8 bolts going into the mounts.
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But the cat is stuck between the crossmember and the body.
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I also had to re-weld my shifter as it was hitting the dash.
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That's where I'm at now, hopefully I'll move the cat in the next day or two, I'm picking up some 3" springs on Friday (replacing my 2 1/2" old spring, including one broken rear). I'll finish drilling the flat skid today and might test fit as well. More photos soon.
 
This looks all too familiar. Im currently stuffing an NV4500 in my TJ with a D300 out back, and a flat skid with 1" of drop. Keep this updated, as you are actually making progress, unlike myself.
 
Also, the cat is pretty tough. Mine has been squashed between the body and the skidplate for about 2 years now with no issues at all.
 
Make sure the driveshaft doesnt bind at full axle droop. Raising the tcase output is the same as adding lift, actually worse because the angle flattens out.
 
I had a lot of problems with heat and vibration/noise when I put a $30 cheaper muffler on. I went back to the stock muffler and Im very glad I did. Leave that heat shield on the muffler and leave the heat shield padding on the body and you should be fine. Thats the same setup Im running.
 
Ya, I have to double check the drive shaft. I've adjusted the pinion as much as I can and I'm hoping it will be enough, I'd rather not bring the t-case back down, but if I lose an inch or so it wouldn't be the end of the world.
 
I would make sure your cat has adequate clearance on all sides. The vibrations through the exhaust will rattle and bang like crazy while driving. I cut my hanger and rewelded it further from the trans/tc.

You may also need to check your exhaust clearance at the front upper control arm.


Just some learnings from my completely flat skid (I used the skid as my transmount).

I like your crossmember... you could always do this to it and get more cat clearance:

ai71.photobucket.com_albums_i135_sff5758_Build_20Inspiration_20Pics_crossmember.jpg
 
The cat is on hold for right now. I checked the drive shaft at full droop and I'm still having some binding issues.

I've found this article and I'm trying out some of the same things. I currently have a 1" motor mount lift, but I've taken it out and creating a 2" MML. Actually with a 2" body lift, things in the engine compartment line up as then did before the lift. I may have to do a little grinding on my rear CV joint and output yoke, though I'm hoping to keep it to a minimum.
 
OK, got the Jeep back on 4 wheels today

Completed the 2" motor mount lift. Everything lines up well, brought the t-case back down a little and the angle is nicer. I ground the joint on the drive shaft a little and with the axle at full droop
the drive shaft angle is finally good. I could grind the yoke a little, but would rather not so I left it.

I changed the shock mounts some and may redo them later, but they work fairly well. I tightened everything down, put the wheels back on and took it for a test drive. Ran well, not many vibrations, cept from the cat and muffler touching the body. Hopefully I'll fix that tomorrow. More photos soon, it's cold and dark out now.
 
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