Trimmy

Well I made a little progress in the last couple days. I thought I would be able to just bolt up my adapter plate and go but it seems there are some small differences between the BEW it was designed for and the ALH its going on. It was mainly turbo oil feed line and coolant lines. I had to slightly bend and reroute the hard coolant line that runs below the glow plugs across the front of the engine, I also had to clearance the adapter plate a little on the engine side to clear these lines as well. I also had to cut and move the oil cooler lines to the bottom of the oil filter housing. My fix for the oil line was a stainless steel flexible unit. I spent an easy 4 hours working on getting this all together. I have it pulled apart now becasue I am waiting on my flex plate and pressure plate bolts.

The Jeep uses 1/2-20x1 flywheel bolts which after hours of calling around the dealership could get them but would take days and cost close to $30. I found a set from Mr Gasket 16.99 minus my 10% military discount. The Mr. Gasket pn is 914

I also found the pressure plates bolts and they are Mr Gasket pn 910.



I also received the elusive clutch/brake pedal assembly today and was so excited I had to put it in.



I also received my HD Offroad Shackle Relocators today.

Trimmy

Well I had to separate the motor and tranny today because I didnt have my flywheel bolts the other day so it was put together just for mocked it up. Well I received my Mr. Gasket pn 910, and 914 today. I had to put the clutch on so I took some brake clean and cleaned both the flywheel and the the pressure plate to get the oil off of it. I then mounted the clutch disk and pressure plate to the motor... It was a very exciting moment. My tracking number for my motor mounts say they will be delivered tomorrow. I just have to get my lift here so I can get everything in.





Here are some pics of the coolant lines and how they had to be relocated.

In this pic you can see the hard 90* turn in the coolant line, I am trying to find another one so I can cut the outlet off and have a 90 welded on there so I can just slide my coolant hose onto it and do not have to worry about that hard 90*.



In this pic you can see a slight bend in the hard line, this is just a SLIGHT bend as it is already kinked from the factory in the position. You can also see what had to be taken off of the adapter plate to clear the hard line also.

Trimmy

Well I got home from work today to what felt like Christmas. I received my Iron Rock Lift kit, my Wagner master/slave cylinder assembly, my upper bushing for my dana 30, and my motor mounts from EVguy. I will have time Sunday and Monday and the goal is to get the all the brake lines replaced, drop the GAS tank, install the lift and modify the cross member to move the tranny mount 4" forward, and hopefully have the motor positioned so I can burn in the motor mounts.







Here is the ABSOLUTE MESS of parts and tools I have... Seeing this picture makes my skin crawl as I hate an unorganized and messy garage and I have both at the moment...

Trimmy

I also drained the 8.8 and pulled the axle shafts to check out the bearings and replace the parking brake shoes and hardware. It all looked good including the new fluid in the 8.8. All I have to do is get the rotors turned and the axle under the jeep and burned in also.

TFitzPat87

Nice! Pumped for this to finally come together!

Trimmy

Yea me too, I am really looking forward to atleast getting the motor and lift in.

XJBARTZ90

Hey man. The jeep is looking good. having a DD jeep with a tdi in it would be sweet.
Quick question, How do u like the iro long arms? Im a little worried on that 10mm bolt for the upper.

RedStar

The progress you've made in 1 month is astounding. Sub'd.

evguy

I used this outlet that just has the main outlet, heater outlet and temp sensor. It sits flush with the back of the vacuum pump to give a bit more firewall clearance.

Trimmy

It's from an auto and I actually just pick one up this morning. I will keep the one with glow plugs in it just in case because the winters in Ohio get below zero so maybe I'll need it one day.

Trimmy

I had one on my 99 and I'm putting another one on this. I really like iron rock products and I have had no issue with the adjuster and if I did I have heard you can put a larger bolt in it

XJBARTZ90

awesome news dude. I bought my BB lift from them and I liked there service.

Trimmy

Well I was able to make some pretty huge progress today. I actually spent about 30 minutes on Saturday doing my IRO HnT SYE. Here she is.





Today was the first day I was able to mount the transmission and the motor up with my starter. First thing I noticed was HPA had the mount for the starter a few degrees off so the hood of the starter was actually contacting the flywheel on one side and about 3/16 away on the other side, no big deal I took my grinder to the starter and shaved about 1/8 of an inch off of it and it had plenty of room to clear to the flywheel. Then I put the Bolted the transmission up or tried to because the starter was in the way of the bell housing. I think I am going to have to cut up the bellhousing to allow the starter to sit in the hole its supposed to be in. I see no other way that the mount will work with the starter other than cutting a chunk out of the bell. So for mock up purposes I left the starter off. I did take into account the length of the starter when I was building the motor mounts.







I did get the motor mounted in the jeep today and it felt great to see the motor in the jeep on its OWN mounts. I did move the motor up around 5" or so. It was the easiest way to mount the engine with all the VW accessories in there ORGIGINAL place. I do not have anything that has less than 1/2" of clearance. It all fit like a glove. I did spend about 5 hours just building the motor mounts. I am 110% percent happy with Randy's (Evguy) motor mounts. He sent me his DIY kit, it was designed for a BEW but I used it on my ALH. I did have to make some adjustments to them but they were everything I wanted. They look amazing and are well built. I have an angle grinder and a welder and could have never made anything that looks this nice and I am more than happy with them.





I also had time (since I spent 12hrs in the garage today) to get the HP D30 and my long arms installed. I chose to use a 4" Iron Rock Long Arm with a Rough Country double shear trac bar and drop pitman arm. I chose the parts because of a few reasons. I had a IRO LA on my last Cherokee and really liked it. but another reason is I wanted to get ride of the passenger side upper control arm since I had a suspicion that it could cause some clearance issuse and it would have if I left it. I also liked this lift becuase it was not a traditional 3 link up front. The upper link in a tradition setup would HAVE cause clearance issues. This kit was EXACTLY what I needed to get this motor and front end together. I also choose the Rough Country trac bar because it gave the most drop on the drivers side, I feel if I would have went with any other TB I MAY have ran into clearance issues there also. I will still need to install longer bump stops but I really have no issues to worry about. I feel I chose exactly what I needed with these parts. I have absolutly NO concernes about the RC TB either, the thing is pretty beefy, 1.25" and .28" wall tubing should handle everything I will throw at it.

Trimmy

The only clearance issue I have is the stock intake. Right now the hood will close but there is about a 1/4 of an inch from the intake to the the hood so I will have to find someone that can lower it about an inch so I have no issues there.

Trimmy

I will be relocating the steering stabilizer mount but here is the clearances on everything.