Cheap Chief

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ross80truck
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Re: Cheap Chief

Post by ross80truck »

Just a quick update, I will get some pics up later. I have a new cross member built and fitted. I started putting a seal kit in the new Dana 300, but after I got into it I did not like the look of the bearings. So, I placed an order today for a bearing kit for the Dana 300. I should be here in a few days. Also located some TF727 shifter linkage from a guy here on the forum. Again, I will get pics up shortly, just wanted to give an update while I had a few seconds.
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

Here are some pics of the progress. I went ahead and bolted everything together and fabricated a new crossmember and while it was all in place I also measured for new drive shafts. I now have everything back out and need to finish welding up the crossmember and I want to add a skid plate under the transfer case as well.

Image

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

As I stated above in an earlier post, I had intended on only putting new seals in the Dana 300. But once I started taking it apart I found some rust and the bearing where pitted. So, I took the Dana 300 completely apart and am now starting to assemble it. Here is a pic of everything apart and mostly cleaned up. I am also twin sticking the transfer case while I am at it. I am in there anyway, so why not?!

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

While I had everything apart I went ahead and modified the new shift rails. These shift rails are the ones that I got in the new kit from Advance adapters. I made a modification to them so that I could shift into FWD high and still keep both pills in place and not worry about it accidentally destroying the transfer case. If you are not familiar with the Dana 300, they are extremely easy to twin stick. But, if you leave the pills in you can only have FWD low, not FWD high. By machine one of the slots a little longer, you can shift into FWD high and still leave the pills in. If you take the pills out, it will allows you to shift one output to low range and the other to high range and will destroy your transfer case. The bottom pic is the modified shift rail.

Image

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

Finally got the Dana 300 rebuilt and back together. Not a bad job, and not that hard to do, I just have been busy and have not had a lot of time to work on it. Probably take about 4 to 5 hours if you were doing it all in one shot. Here is a pic of it back together and ready for paint and another pic of it painted. It is extremely cold here today, well at least it is cold for Texas. So, it will take a little while for the paint to dry. Next I need to finish welding up the new cross member and then stab everything back into the jeep. Then onto transmission shift linkage, downshift cable, drive shafts, and exhaust. Oh yeah, and lock out hubs and transfer case linkage and put the tunnel cover back in, and then carpet and seats back in. Okay, I still have a little ways to go.

Image

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301

CherokeeJim
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Re: Cheap Chief

Post by CherokeeJim »

Hi Ross!

Hey man, nice rig and awesome work!! :-bd :fsj: :fsj:
I'm located in Copperas Cove, TX if you ever want to get together.
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'77 Cherokee 6" lift/6.6L/TH475/BW1339/D44s/4.56s/35x12.50x15s/ Detroit rear :fsj:
'82 J10 6.0L/6L80E/Atlas 3.8/SOA with 2" front springs/ 63" springs inboarded/D60F/Spartan Locker/14Bolt/Detroit 4.56s/42s
'71 J4000 on 81 J10 frame/6bt/4500/203-205/D80F D80R/ARB/Spool/5.13s/42s
'79 Cherokee 4dr 6.6L/TH400/BW1339/D44s/3.54s :fsj:
'08 Tundra 5.7L 3" lift/33s
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Re: Cheap Chief

Post by ross80truck »

CherokeeJim wrote:Hi Ross!

Hey man, nice rig and awesome work!! :-bd :fsj: :fsj:
I'm located in Copperas Cove, TX if you ever want to get together.
Jim,
Definitely need to get together sometime. Are you part of the "5 Hills Jeep Club"?
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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ross80truck
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Re: Cheap Chief

Post by ross80truck »

Learned a few lessons when installing everything back into the jeep. First thing was that I did not realize that there was a specific orientation for the torque converter to the flywheel. Once the transmission bolted to the engine, I went to bolt up the torque converter and only one or two of the bolts would line up. Went to rotate the torque converter and found out that the weight on the flywheel and torque converter feet hit and would not let them rotate past each other. So, I loosened the bolts on the transmission and slid it back and got everything rotated correctly. That is when I realized that there is a mark on the torque converted that you can see through a window in the flywheel that shows you they are lined up. So, needless to say I lost an hour on this lesson.

Had to get new drive shafts for the swap. The TF 727 is a lot shorter than the old TH400. I got these from Tom Woods.

Image

Here are the drive shafts installed. The rear drive shaft installed nicely. I was afraid there would be some clearance issues between the fuel tank and drive shaft, but everything looks nice. The front drive shaft was a different story though. I installed it and then found out that at full drop on the front axle the drive shaft binds with the yoke on the transfer case because of the steep angle. I called Tom Woods and talked to them. There are a couple of thingd you can do here. If it is close, you can just grind some clearance and let it go. If it is really bad you can install an offset U-joint. Luckily mine was not that bad and after some light massaging I was able to get it to rotate at full drop without binding. I would not be happy with this steeper angle if it was still going to be all wheel drive, but since I am now going to have lock out hubs and 2wd in the transfer case I am not concerned with the excessive angle. There is a 3rd option which would have been to go to a high angle CV style front drive shaft, but again, I have clearance issues with the pan on the transmission and do not know if it would have fit.

Image

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

Last night I installed my new front lockout hubs. Probably was the easiest part of the whole swap. I don't know why, but lock out hubs are cool.

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Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

One of the other major hurdles in this swap is that the factory exhaust does not fit anymore. Luckily for me, a budy of mine that keeps borrowing my trailer has a mechanics shop and also builds exhaust. So, I called in a favor and he built a completely new exhaust system for me. I was very happy with how it turned out. Here is how it looks.

Also, in the first pic you can see how close the front drive shaft is to the transmission pan. It looks like it touches in this pic, but the drive shaft actually comes out just below the pan.

Image

He fabricated that y-pipe himself. Looks awesome and it only took him about 10 minutes to do. I guess if you know what you are doing.

Image

Image

Because this is an offroad toy, I wanted everything tucked up underneath nice and tight. So, he ran it close to the floor pan and then gave it this little turn down right at the back.

Image

Plenty of clearance on the shock and plenty of clearance between the muffler and drive shaft.

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301

chevelleguy
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Re: Cheap Chief

Post by chevelleguy »

That's going to fill the cabin with exhaust gas. You need to dump it out from under the truck.
David
'83 Wag Limited, 360/727/pinned 229/D44 front/AMC20,lockrite,rear/6" BJ lift w/ 35/12.50/15 M/T Baja MTZ/ Pro-Jection EFI.

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serehill
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Re: Cheap Chief

Post by serehill »

Nice truck But I do agree on exhaust don't roll down the rest window either.

Really nice rig.
1980 Honcho 258 4 speed mostly stock with 4 " lift.

WIP

You know the rude dude from IFSJA


1980 Cherokee wrangled & mangled
MSD complete system
Eddy intake
Holley 650
Comp cam 270H
4" Rusty's
Ramsey 12K winch
208
Built to drive not sit in the garage.


No longer strangled. I didn't build it for anyone else.
If you can't improve it why waste your time?
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fulsizjeep
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Re: Cheap Chief

Post by fulsizjeep »

:-bd Good Stuff. :fsj:

I agree on exhaust... If there is any air circulation in the cabin while going down the road, exhaust is going to get sucked in around the tailgate gasket area, window, etc. Even with new gaskets in the tailgate area, these things are not 100% sealed and breath outside air in. That is why stock exhaust exits out the side.
Flint Boardman
88 GW, 401/727/208, 5" lift, D44s/4.10s/locked up, 35s
https://jubileejeeps.org/quadratrac
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Re: Cheap Chief

Post by ross80truck »

Thanks for the heads up on the exhaust. That really stinks that I may have to move it. I really like it where it is at. I have a bigger problem to tackle first though. I now have a big puddle or tranny fluid under the jeep. I guess the TF 727 is notorious for the seal around the shifter lever leaking. And guess what, mine is! So, off the the transmission shop to get that fixed. They said they could fix it without pulling the transmission. So, once I get that back and everything else together I will see what the exhaust is like and go from there. It will not be a big deal to rout it out the side. I just really liked it all tucked up nice and tight. I am assuming even though it is right at the rear bumper that you all still think it will be a problem?
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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fulsizjeep
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Re: Cheap Chief

Post by fulsizjeep »

ross80truck wrote:Thanks for the heads up on the exhaust. That really stinks that I may have to move it. I really like it where it is at. I have a bigger problem to tackle first though. I now have a big puddle or tranny fluid under the jeep. I guess the TF 727 is notorious for the seal around the shifter lever leaking. And guess what, mine is! So, off the the transmission shop to get that fixed. They said they could fix it without pulling the transmission. So, once I get that back and everything else together I will see what the exhaust is like and go from there. It will not be a big deal to rout it out the side. I just really liked it all tucked up nice and tight. I am assuming even though it is right at the rear bumper that you all still think it will be a problem?
There is an inexpensive tool you can buy to do the shifter seal. The back end of a Cherokee/Wagoneer is a big vacuum for air, dirt and moisture as you go down the road. Routing it out the side so the exhaust can get away from the Jeep is really the only way to avoid fumigating yourself.
Flint Boardman
88 GW, 401/727/208, 5" lift, D44s/4.10s/locked up, 35s
https://jubileejeeps.org/quadratrac
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Re: Cheap Chief

Post by ross80truck »

Okay, it is official, my "Not so Cheap Chief" is back on the road. I got it back from the transmission shop late Friday and finished putting the interior in on Saturday morning and drove it all weekend. First, you all were right, I am going to have to redo the exhaust. If my rear window is up it is not that bad, but if my rear window is down, it sucks exhaust fumes into the cab bad. Other than the exhaust issue I am happy so far with the conversion. I have just a few small things to wrap up like I need a 90deg speedometer cable adapter for the transfer case because there is not enough room for the cable to come straight into the transfer case. I will order that today from transmissioncenter.net. I also need the neutral safety pig tail for the TF 727 and I can get that today from BJ's. Here is a pic of the twin Dana 300 stick shifters sticking through the floor. Yes, I know that they look cool!

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

Now that I am done and it is on the road, here is a complete list of what I had to buy and do in order to do this conversion. Remember, I did this on a 76 Cherokee Chief which has a passenger side drop front axle. If you have a drivers side, you are going to have to buy a flip kit and possibly cable style shifters. Also, everything in my case was a bolt together, but nothing was a drop in. Meaning the engine, transmission and transfer case all bolted together, but I had to make a new crossmember to mount it. Also I am running a 4" lift with 1" shackle lift. So, I have about a combined lift of 5". This if important for drive shaft clearance in the front.

- TFT727 out of a 1985 Jeep Wagoneer
- Torque converter out of an 1985 Wagoneer
- Factory 401 starter
- Dana 300 out of a 1982 CJ7, Passenger side drop
- Advance Adapters Twin Stick Kit
- Lokar KD-2727HT Kickdown kit, you could use the factory linage off the same jeep you steal the transmission linkage from here if you wanted to
- OMIX-ADA Dana 300 trasfer case gasket kit
- TCI-Auto TFT 727 pan gasket and filter kit.
- Flex plate for a 401 to TF 727. I bought mine for an 72 AMC Ambassador with a 6.6L
- New front and rear drive shaft. I got mine from Tom Woods.
- I used the shifter linkage out of a wagoneer that originally had a TF 727. One of the linkage supports should have bolted to the frame. Since mine did not have bolt holes there and there was no easy access, I just welded it on.
- 90deg angle drive for speedometer cable on transfer case
- Neutral safety pig tail for the TF 727
- Exhaust will have to be redone because the factory exhaust will not fit
- You will have to build a custom cross member to mount the transmission and transfer case. I also welded a tab on it for the e-brake cable
- I had to grind a little on the front yoke of the transfer case to keep the front drive shaft from binding. Take a close look at this and there might be a better way to do it. Measure your angles and talk to the drive shaft shop before you order your drive shafts. They may be able to offer something different than what I did.
- I had to redo my transmission cooler lines because they go to the opposite side of the transmission compared to the TH400.
- Warn lock out hubs.

I think that this is it. If I remember something or if you all can think of something I will come back and edit this post so that it will be a complete list. Please feel to ask any questions you might have.
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

This is totally separate from the transmission install, but I had ordered these electric fans a while back and while I had time this weekend I installed them. This is a dual electric fan set up that I bought from Summit Racing (part # SUM-G4851). I had to trim about an 1/8" off both sides of the the fan shroud in order for it to fit, but I really like it a lot and it moves an awesome amount of air. I hooked it up using a fan control kit I got from summit as well, Part # HDA-3654. All total is cost about $300 for the setup. I really like it though and I think it will help keep the jeep cooler in the summer heat and help the AC be cooler. I did not have a fan shroud on my old mechanical fan and the old fan was bent. So this is a big improvement over what I had.

Image

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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Re: Cheap Chief

Post by ross80truck »

Well, the "Not So Cheap Chief" has been running flawlessly for a while now. It has been driven daily since February and the only problem I see is that the fuel mileage sucks. So, since I figured the mileage can't get any worse, I should go ahead and at least have more power. So, after a quick call to Summit Racing and a few days of waiting, the new parts have arrived. I just went with the basic Edelbrock Performer stuff. Most of the time I want the power at the low end, so the cam and intake are both designed for idle to 5500 rpm. I figured I would go ahead and put a new double roller timing chain on while I was in there. I did a compression check on the 401 before I ordered the parts just to make sure my bottom end was good before I put more money into the motor. All 8 cylinders ranged from 150 to 160. So, I figured that was pretty dang good. I really like to do all the work on my Jeep myself, but I have a friend that owns a Auto Repair business and he owes me a favor. So, I think I will let him do the work putting all this on since I am so busy with my business and do not have the time.

Image
Priorities
1. God
2. Wife ( Sarah )
3. Children ( Lane & Dirk )
4. Work
5. Jeep

Man it is hard to keep them in the right order!

85 Wagoneer, 6bt, NV4500, Black Box, NP205, D60 front, Corp 14 rear http://fsjnetwork.com/forum/viewtopic.php?f=36&t=1446
76 Cherokee Chief - Cheap Build - SOLD http://fsjnetwork.com/forum/viewtopic.php?f=12&t=2605
81 Jeep Scrambler http://www.fsjnetwork.com/forum/viewtop ... 301#p97301
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243
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Re: Cheap Chief

Post by 243 »

Nice Chief!

Working my way through your build during my lunch hour, I see a lot of cool work and probably more to come.

The bumpers is slick.

Image
1978 Cherokee NT, 5.3/4L60/NP241 in Progress
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