Search and Rescue JoKe (2014 JK)

[SuperBuickGuy]

thinned wiring harness ready to go in

need a few days of less than 110 degrees in the shop but this is getting close

 

[SuperBuickGuy]

starter is wired. now for all the rest

also wired the speedo and t-case indicator
...next up, computer holder

 

[SuperBuickGuy]

a friend helped with inside and got the gauge pod in place

remember I asked why the other r2.8 conversion Jeep moved the box 90 degrees? I know now

time for a computer mount

and all that is left is paint

 

[SuperBuickGuy]

and a bit of white paint

 

[SuperBuickGuy]

lights are on

 

[SuperBuickGuy]

pay attention to the arrows on the housing, not the instructions in the book...

and with that fixed, first fire
[VIDEO]

 

[SuperBuickGuy]

and wiring continues until the world ends

where I'm at. I've got nothing accomplished. The ignition switch will power the motor and turn it off, however, getting it to engage the starter has been a challenge.

I'm stepping back from that - worst case scenario, it gets a button... but I have a lot of other things I can do, so I'll continue to mess with it while I go onto my next challenge - wiring the fan to work. Once that is done, it actually could be driven on the road. Speedo works, all the dash emojis light up (festive) even ones I didn't do anything with (sway bar disconnect error light).

 

[SuperBuickGuy]

with how much this motor costs, I'm surprised you have to go aftermarket to get the flange

not just that but the m10x1.25 nuts aren't included for the exhaust...
and that other piece... 60 bucks... no
installed

304 16 ga stainless

and tips

I didn't finish because I am out of oxygen for my torch - need to make and install hanger - all of which require a 90 degree bend
also fixed the jack on my trailer so I can haul it to a friend to figure out the ignition situation

ignition powers on, but won't crank. Occasionally it does but then shortly after that it won't crank at all (even with a bypass).... also plumb the A/C

 

[SuperBuickGuy]

So close.
intake, done

exhaust

done

what's left for me - put the interior back together.

then it goes back to Woodinville to a friend who loves wiring... he'll solve the ignition switch issue, wire the a/c pump and tie the temp sensors into the diesel sensor (thus enabling the fan circuit). finally wire the oil pressure switch and determine if we can fool the tach into taking the diesel outputs....

once it gets back, I'm doing a different 'house storage' system that integrates solar panels, and a lithium battery pack that also runs the engine-off a/c system.

this I'll publish later but the nutshell is we're using Zero Breeze a/c and their e-generator (batteries). I also think I can charge the reserve system with a simple 12v - 110v inverter. This should make the system easier and portable between our K9 rescue rigs.

 

[SuperBuickGuy]

well, now it's ready to go to the wizard...err... electrician
bolted the interior all back together.

when it gets back, I will have some house wiring (meaning, the stuff that doesn't run the vehicle) to resolve but it should be drivable

 

[SuperBuickGuy]

Update. The starter is bad. Waiting on replacement - yep, get to pay for it then hopefully get reimbursed later. Not pleased.

 

[SuperBuickGuy]

so back to this... first problem, went to the gas station and realized I need a bigger hole

I have a list of stuff to fix and finish... it's not terribly long but the fuel fill and the gas pedal are at the very top of the list...
To be honest, I have no idea (not in the instructions either) about where the pedal should be mounted in relation to your foot. I know for 100% sure that spot isn't found by using the Jeep pedal studs... go figure...
What else? cabin wiring, make things look pretty under the hood, realign the steering wheel, put new tires on it... then let my wife drive it for awhile to get the 'real' list... but before i give it to her... that fuel pedal and fuel filler will be fixed.

 

[SuperBuickGuy]

10 years since I first drove this.... seems like yesterday

 

[SuperBuickGuy]

back to the Jeep. The weird sound - almost like a boost leak but not quite. I hope this is the problem

I think I'll weld the flanges together then use a V-band to make it removeable. I spent some quality time on this trying to find the noise... hope it's it. Otherwise, this may go do its purpose this week.... Colorado needs some love (after all, she put 75,000 miles on it since she got it last March)... so this goes back into service. Still have several things to do but none of them prevent it from being used while doing that stuff:
- for those curious-
- back 1/2 bench
- install the zero breeze battery
- install a charge plug on the outside
- turn off the dash lights

things I'll do before it leaves
- coolant reservoir (oops, forgot that)
- exhaust leak
- shore power plug
- straighten steering wheel
- figure out backup camera
- and most importantly, figure out why I'm getting a 3597 code (unstable switched power)

it does drive fine, if not a bit slow. Once it gets up to speed, cruising at 80 isn't an issue. It's funny, you never notice the dash light issue sure - they're on, but really not noticeable.

 

[SuperBuickGuy]

Wiring
switched a wire and now have a master switch

off

on

and now with a cover

as the top doesn't leak enough.... a new hole

for shore power

and riveted in place

and we need a seat in back
so why a cooler seat?

whip up a couple brackets

just need to strap it down and craft a couple cushions

 

[SuperBuickGuy]

new Sandpoint shop... at least, temp shop. done vehicles are there, this one is next to travel this week

but first, fix an exhaust leak

with a v-band

then install an overflow bottle

and PCV line

and finally install the cooler/seat

pad comes later this week.... then onto the trailer and northbound.

 

[SuperBuickGuy]

Soooo
long story short, bottom end sounds like it's losing a rod cap.
Took it to Cummins to diagnose the throttle issue and an electrical gremlin. Both were more installer error.... but when they got done, suddenly it had a rod knock.
We thought it was coming from the transmission.... it's not

ATM it's parked, I'm so disgusted with this thing that I frankly don't want to look at it. I'll get back to it but tomorrow will be the fun of finding out how to get a new motor under warranty.... wish me luck

 

[SuperBuickGuy]

No worries - not a rod knock
started with a clean pan

but wait, no fuzzies

there is no airgap .... ugh, all the worry for nothing

For those who wonder what this looks like installed

I know it looks like it fills the space, thing is, to not have to shorten driveshafts, enlargen the tunnel, and figure out a new shifter for the tr-4050... the motor is at least 4" forward.... that said, it does take a lot of width

 

[SuperBuickGuy]

under 'rattle reduction' this was added

right here

 

[SuperBuickGuy]

this should surprise no one, I found the problem in some random place.... the article describes the issue and what I'm hearing

What's That Sound? Gear Rollover And How To Reduce The Noise

Gear rollover is a common noise that comes from a manual transmission. We look at what gear rollover is and how to reduce it.

www.dragzine.com

and no, I'd never heard of this before... but the symptoms and noise are exactly the issue.... on top of this, I had it up on my lift today and really searching for the noise source