79 Cherokee Chief Cummins 6bt with ford one ton axles

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lobie
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Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:38 am

3/10/12

The back side of the holder. Notice the small hole:

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I drilled the hole out enough so the LED assembly would snugly fit without glueing:

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I feed the LED through the hole and pulled it till it bottomed out:

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The back side with the wires:

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
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lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:38 am

3/10/12

Next I striped the wires. I stripped them long so I could wrap it and hold it in place while I soldered it:

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The wires are soldered to the lower portion of the terminals. Wires soldered and the excess wire cut off:

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Assembly placed back in the back side of the gauge:

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Thats it. Pretty simple and it can be converted back without buying new bulb holder.
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

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lobie
Posts: 486
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Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:39 am

3/10/12

I started working on the water inlet manifold to the engine. I have to modify it for a couple of reasons. First off it points straight to the fender and second the inlet is 2.5" diameter.

I am going to modify it to point to the radiator and reduce the outer diameter to 2". It should be fine as far as water flow is. The outlet is 1.75".

Since it is cast iron I will be pre heating it and post heating it in the oven. Didn't really feel like doing it tonight.
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

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lobie
Posts: 486
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Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:40 am

3/11/12

Only thing to mark off the list today is the throttle cable.
Mounted the ps filter. Once my fittings come in the ps/hydro boost plumbing will be done.
Also modified my water inlet for the engine. It's still in the oven cooling. Finish it and the radiator plumbing this week.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:40 am

3/11/12

I toyed around with my adjustable proportional valve. It's a summit brand but as we all know they don't really make any products. This is the one I got:
www.summitracing.com/parts/SUM-G3905
But it is really this one once u pull the sticker off:
www.summitracing.com/parts/WIL-260-8419

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Last edited by lobie on Fri Mar 29, 2013 9:41 am, edited 1 time in total.
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:41 am

3/12/12

Didn't get too much done this evening. Got the coolant inlet done and the lower hose plumbed. Still need to plug off the heater return till I hook that stuff up.

I had a seeping leak around the oil pan so I've been wanting to reseal the oil pan. Took it off tonight and cleaned the inside while I had it off. No surprises.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:42 am

3/14/12

Gave her a lube job tonight

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Also got my temp sender in today and finished the radiator hoses. Filled it full of coolant.

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My tool to get fluid in the tranny and tc

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:43 am

3/15/12

Here's some overall shots.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:43 am

3/17/12

It's alive. I purged all the lines all the way to the injectors to make sure there was no air in the lines. It barely turned over before it started. Here's a short video.

http://i1121.photobucket.com/albums/l50 ... 45fc11.mp4
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:44 am

3/18/12

As good as I am of making sure I finish and check things I do miss once in awhile. Yesterday I cranked the engine for the first time in almost 2 yrs.

Although it cranked right up and no major problems I did forget one thing. Since I rebuilt the ps pump I should of got all the air out. I didn't. I noticed there was no fluid returning to the tank. After I got all the air I could out of the lines it worked perfect. Since the brakes aren't plumbed I ran some lines to the top to test out the hydro boost. You could basically press the pedal with your pinky. So far so good and what a rewarding wknd.

This week the plans are to go through the whole brake system and clutch so I can order all the parts. Getting closer. :fsj:
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:44 am

3/19/12

I didn't manage to do much this evening. I did save myself $120. One of the rear brake calipers had the bleed valve broke off in it. I was planing on buy two new ones since I tried getting it out with an "easy out" but it broke off inside. I used my dremel and about a hours time I got it out.

I order the brake plumbing today so looks like I'll have the brakes plumbed up this wknd.
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:45 am

3/20/12

Put the rear rotors and pads on this evening. Started the front but one of the caliper pins wont come out. Heat, hammer, nothing. Letting it soak over night. I've destroyed the top of the pin beating on it. I'll get it out and get some new pins.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:45 am

3/21/12

I ran into a couple bumps tonight. I got the caliper pin out and some new ones. I put the caliper on and noticed the rotor was about a half inch to small. I looked the rotor up for the 2006 f250 and the diameter is 13.66" which is bigger than the one it came with. No big deal, I'll spend some money and buy new rotors....done.

I left it alone and put the calipers on and was puting the wheel/tire on. It wouldn't go. The calipers are hitting the wheel. The wheels are off a f250??? 16" wheels. I've done it in the past with fitting 15" wheels on 14 bolts with disc brake conversions so I granded the caliper down. It didn't take much. I'm confused why it didn't fit. I still have the drivers side to do so I'll finish it tomorrow.

Here's a pic of the caliper and small rotor.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:46 am

3/23/12

finished the front calipers today. Theses things are massive. Also put the new steering coupler on. Waiting on the brake lines. Thought they would be here today. Was planning on getting the lines done this wknd. Think I may fit the drive shaft up. Did get the slave cylinder for the clutch today.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:47 am

3/24/12

Tried working on the jeep today. Was doing the rear drive shaft. Got the rear suspension as low as I could to measure for max length. (39.25", so I don't forget.

I was pressing the u joints out of my drive shaft to take it apart and it came flying out of the press. My foot, the same one I broke last year was in the way. At least it didn't hit the plate in my foot cause it probably would have bent it.

Here a pic of the only progress today.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:47 am

3/25/12

Got a little done this evening. Front and rear diff oil. Tanks to Jeepguyp for the free synthetic. Saved me some money. Also got the rear drive shaft and spring perches welded.

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Front Dana 60
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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:48 am

3/27/12

Rear brakes are plumbed.

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:48 am

3/31/12

My list is getting smaller. Worked for about 12 hrs today and I'm beat. I have no pics but those that have been following this build can see the progress from the smaller list below.

I plan to bleed the brakes and clutch as well as go through a bolt and weld check tomorrow. I will pull it out the garage and take it around the neighborhood for the first time in over 13 months. The air filter and plumbing for it will be here next week.

I also will address a clearance issue with the tc. There's about an 1/8" gap in one spot. Will cut the floor and reweld. It's about a 3"x6" area.

As I was setting up the clutch I noticed that I may not have enough throw in the pedal. If I can't disengage the clutch I will address it tomorrow.

The spare tire and wheel have been ordered and should be here next week.

Overall I have meet my goal almost one month ahead of schedule. Had planed to be at this stage early May so I could work out any bugs before going to ECI in June. I've busted my but the last month. Going to spend some time with the family and go camping in a couple of weeks.


Jeep To Do (I'm sure it will get bigger):

front drive shaft
spare tire/wheel
rock sliders
air filter
shift boot
tc boot
plumb air filter
fix rear window rattle
tighten and cut tops of rear u bolts
tighten top & bottom front ball joints
tc floor clearance
check lights
check all welds
check all bolts
final check over
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:49 am

4/1/12

It drives :fsj:

My son and I bled the brakes and the clutch. The clutch is pretty hard to push. The pedal throw isn't Very long so there isn't much of a lever arm on the mc. It's good theropy for my leg

Jeepguyp and I took it through the neighborhood for the first time. Here's a video. Some how while doing the clutch mc I knocked the ground for the gauges off. It's fixed now.

http://i1121.photobucket.com/albums/l50 ... 139f78.mp4
77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com

User avatar
lobie
Posts: 486
Joined: Wed Aug 03, 2011 7:17 pm
Location: Fountain Inn, SC

Re: 78 Cherokee Chief Cummins 6bt with ford one ton axles

Postby lobie » Fri Mar 29, 2013 9:50 am

4/3/12

Got the air filter done. Took the first trip out. Eating Mexican, beer and tequila. :thumbsup:

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77 Wagoneer | 6.0 | TH400 | NP205 | Sterling 10.5 | Dana 60
07 6.7 Cummins 2500 4wd

http://www.lobie4x4.com
http://www.cfsjc.com


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