05 Flame Red TJ Build

[Wildman]

The new shoes will likely be Cooper STT Pro’s in 35x12.5r17 or 315/75/17. I’ll also look at Baja Boss’s, but if I find a 36” I’ll look at that. Right now my mind is occupied with the auto swap, but if I see a sale I’ll be selling my 35’s on 15’s and moving on to 17’s. I believe @kiwi was interested in them. I think you’ve given him some parts IIRC!

Since you drive yours on the road more I won't recommend more aggressive or quick wearing tires. Ryan seems to be very happy with his Baja Boss tires.

Yes that auto swap is going to be a game changer for you. You might need to be looking at new gearing once you do the auto swap... Take a step back and breathe, that auto swap isn't any harder than anything else you've undertaken. Your best thing you've got going is that you have an example sitting in the driveway. Also take your time.
My only recommendation would be to possibly look at replacing all the plastic looking with the cloth loom from Painless Wiring. I really like working with it a lot more than the plastic looming.

Only 36" tires I know of are Interco/TSL which I thought were a no no for you? I've had good luck with my TSL tires over the years but I know you had balancing issues.

 

[JMT]

Since you drive yours on the road more I won't recommend more aggressive or quick wearing tires. Ryan seems to be very happy with his Baja Boss tires.

Yes that auto swap is going to be a game changer for you. You might need to be looking at new gearing once you do the auto swap... Take a step back and breathe, that auto swap isn't any harder than anything else you've undertaken. Your best thing you've got going is that you have an example sitting in the driveway. Also take your time.
My only recommendation would be to possibly look at replacing all the plastic looking with the cloth loom from Painless Wiring. I really like working with it a lot more than the plastic looming.

Only 36" tires I know of are Interco/TSL which I thought were a no no for you? I've had good luck with my TSL tires over the years but I know you had balancing issues.

Well dang. I just got some new high temp split loom on Sunday. I can send it back and go with the cloth if it’s better and easier to work with. I wondered about that. The cloth looks prettier and easier to work with, but it looks like it would pick up a lot of grime.

I did a lot of looking at Kaleb’s wiring when he had the fender off for the torque box replacements. I’ve got everything labeled on my 42rle harness now.

Yes, gearing will be another issue. I’m looking at helping K regear his, and my son in law wants to eventually regear his ‘15 Ram 1500 Eco Diesel, so I may be getting some practice under my belt. Of course I’m worried about vibes on mine since they already kick in about 75mph.

 

[Wildman]

Well dang. I just got some new high temp split loom on Sunday. I can send it back and go with the cloth if it’s better and easier to work with. I wondered about that. The cloth looks prettier and easier to work with, but it looks like it would pick up a lot of grime.

I guess it comes down to personal preference. I don't like the plastic loom getting brittle over the years and breaking & cracking or getting hard so you can't open it to get at the wires. Unless you have a serious leak I don't see the cloth loom getting all that dirty.

I did a lot of looking at Kaleb’s wiring when he had the fender off for the torque box replacements. I’ve got everything labeled on my 42rle harness now.

Having all the plugs labeled is a big help or it was for me at least. I really like having my plugs all labeled.

Yes, gearing will be another issue. I’m looking at helping K regear his, and my son in law wants to eventually regear his ‘15 Ram 1500 Eco Diesel, so I may be getting some practice under my belt. Of course I’m worried about vibes on mine since they already kick in about 75mph.

You might want to start watching for a hub kit too. If you decide to do it yourself just take your time and don't be in a hurry. It's buying all the tools needed that hurts more than just buying two sets of gears and TAD's . At least once you buy the tools you don't have to buy them again.

 

[JMT]

For anyone doing a NSG-370 to 42rle swap, pages 867-903 in the 2005 FSM are very helpful. I just printed them all out, removed the pages for Right Hand Drive and 2.4L, x’d out export only and RHD connectors, then started studying.

 

[Wildman]

For anyone doing a NSG-370 to 42rle swap, pages 867-903 in the 2005 FSM are very helpful. I just printed them all out, removed the pages for Right Hand Drive and 2.4L, x’d out export only and RHD connectors, then started studying.

I like printing off just the pages I need which IMO is a lot better than paying for a printed FSM since I can mark up the pages or get them greasy and not worry about it. I can remember trying to read thru smudged or grease covered print wondering what it said. With it in PDF format you can read it on your computer or tablet & print off the stuff you need.

You'll get this.

 

[JMT]

@mrblaine kindly sent me some connectors and adhesive lined heat shrink to try while fixing my engine and transmission harness. These look great, so narrow and just right to get the job done and be able to keep everything inside the loom. Fun packaging Blaine!

 

[freedom_in_4low]

I like fabric loom too. I've used it a lot since I first tried it on my Harley, tucking the harness up under the tank and internal to the handlebars. Split loom was just too big and round to do that, but even when space is not an issue I prefer the look.

 

[UKTJ]

If Revolution doesn't restock the usa front inner axles any time soon I may just need to part it out. Its getting lonely sitting on jack stands.
View attachment 484580

Guessing you have had no new news over the Christmas period from Revolution since this post. How long have you been waiting? I bought new gears in November in the Black Friday sale and they have still not been sent. They said they were in stock when I purchased but then said they didn't have the bearings*. I've called them a few times (not cheap when calling from the UK and you get put on hold while they try to find the right person to speak to), but both times was told the bearings would be in "next week", however three weeks on from the last call and the order has still not shipped. I know a lot here are big fans of Revolution, but I'm unimpressed - they know I have contacted them and whay they have told me, they have my email so it wouldn't be too hard to email to explain they do not have the bearings yet.


* I ordered the gears with the Koyo bearings, these show as out of stock currently while the Timken bearing set claims to be in stock. I bought the Koyo for three reasons:
1. In a recent regearing thread somebody ordered gears with the timken bearings, but then hot a mix of bearing sent which ultimately caused a problem as he used a Timken bearing for set up and the final Koyo one was not identical.
2. At that time (September) it was the Timken bearings that seemed to be the problem sourcing,
3. Given 1. and 2. above I saw little point paying a $60 premium for the set with Timken bearings.
It seems when they are short on Timken bearings Revolution will substitute less expensive Koyo bearings, but having accepted an order saying they have Koyo in stock don't do the reverse swap when they don't actuallg have the bearings.

 

[Alex01]

Guessing you have had no new news over the Christmas period from Revolution since this post. How long have you been waiting? I bought new gears in November in the Black Friday sale and they have still not been sent. They said they were in stock when I purchased but then said they didn't have the bearings*. I've called them a few times (not cheap when calling from the UK and you get put on hold while they try to find the right person to speak to), but both times was told the bearings would be in "next week", however three weeks on from the last call and the order has still not shipped. I know a lot here are big fans of Revolution, but I'm unimpressed - they know I have contacted them and whay they have told me, they have my email so it wouldn't be too hard to email to explain they do not have the bearings yet.


* I ordered the gears with the Koyo bearings, these show as out of stock currently while the Timken bearing set claims to be in stock. I bought the Koyo for three reasons:
1. In a recent regearing thread somebody ordered gears with the timken bearings, but then hot a mix of bearing sent which ultimately caused a problem as he used a Timken bearing for set up and the final Koyo one was not identical.
2. At that time (September) it was the Timken bearings that seemed to be the problem sourcing,
3. Given 1. and 2. above I saw little point paying a $60 premium for the set with Timken bearings.
It seems when they are short on Timken bearings Revolution will substitute less expensive Koyo bearings, but having accepted an order saying they have Koyo in stock don't do the reverse swap when they don't actuallg have the bearings.

I'm waiting on inner axles. I had the disocvery series and managed to blow a ujoint 5 times over summer resulting in 2 warranty claims. The first time they sent a new set no questions asked. The second I requested they credit me the cost of the discovery and apply it to the USA version.

I've been waiting since late October. Most websites still say 45-60 days until delivery but that date doesnt seem to change.

 

[Wildman]

I'm waiting on inner axles. I had the disocvery series and managed to blow a ujoint 5 times over summer resulting in 2 warranty claims. The first time they sent a new set no questions asked. The second I requested they credit me the cost of the discovery and apply it to the USA version.

I've been waiting since late October. Most websites still say 45-60 days until delivery but that date doesnt seem to change.

Might be time for some RCV axles for you?? What u-joints are you using? I had Alloy USA shafts in my front axle and was running stock u-joints and blew one which took out the inner long shaft. When I got my replacement shafts I upgraded to Longfield u-joints.

 

[Alex01]

Might be time for some RCV axles for you?? What u-joints are you using? I had Alloy USA shafts in my front axle and was running stock u-joints and blew one which took out the inner long shaft. When I got my replacement shafts I upgraded to Longfield u-joints.

5-760x in disocvery.

The usa shafts use 1350

 

[JMT]

Step one in the transmission swap was to label and repair all the connectors on both engine harnesses. Apart from a couple I need to steal from the old harness when I do the swap, I finished that today. See all my colorful labels?

Some of the wiring was a rats nest and not waterproofed. I used some solid barrel non-insulated butt connectors that Blaine sent along with adhesive shrink wrap. When I get an assortment of rig terminals in I’ll finish what I started and use a large heat shrink to protect it.

My next step is to repair all the loom. I’ve got new loom and harness tape. Blaine gave me some good tips on the process. I’ll start this week and take my time. I need to get the dash harness on order so I can be ready to get it sorted.

It’s really informative to spend time in the FSM and get to know all the connectors and what stuff does. Hopefully it will help me get around an engine better in the future.

Also hoping to resolve an issue with the PDC housing soon.

 

[NashvilleTJ]

Step one in the transmission swap was to label and repair all the connectors on both engine harnesses. Apart from a couple I need to steal from the old harness when I do the swap, I finished that today. See all my colorful labels?
View attachment 487007

View attachment 487008
Some of the wiring was a rats nest and not waterproofed. I used some solid barrel non-insulated butt connectors that Blaine sent along with adhesive shrink wrap. When I get an assortment of rig terminals in I’ll finish what I started and use a large heat shrink to protect it.
View attachment 487009

View attachment 487010

My next step is to repair all the loom. I’ve got new loom and harness tape. Blaine gave me some good tips on the process. I’ll start this week and take my time. I need to get the dash harness on order so I can be ready to get it sorted.

It’s really informative to spend time in the FSM and get to know all the connectors and what stuff does. Hopefully it will help me get around an engine better in the future.

Also hoping to resolve an issue with the PDC housing soon.
View attachment 487011

Is that hole the problem? Do you just need a new housing?

 

[JMT]

Is that hole the problem? Do you just need a new housing?

The PDC housing has three parts, as you may know. The bottom and middle parts are broken on the 42rle harness. I have a good one on my current NSG harness. I fiddled with it, wanting to swap it over, but not sure how to take apart the middle part with all the yellow trays and fuses or relays. Talking with Blaine he said it has to come apart somehow because they wouldn’t have put all the pins in with it together. He’s going to talk with his worker and figure out how to get it apart.

 

[Alex01]

The PDC housing has three parts, as you may know. The bottom and middle parts are broken on the 42rle harness. I have a good one on my current NSG harness. I fiddled with it, wanting to swap it over, but not sure how to take apart the middle part with all the yellow trays and fuses or relays. Talking with Blaine he said it has to come apart somehow because they wouldn’t have put all the pins in with it together. He’s going to talk with his worker and figure out how to get it apart.

 

[Mike_H]

The PDC housing has three parts, as you may know. The bottom and middle parts are broken on the 42rle harness. I have a good one on my current NSG harness. I fiddled with it, wanting to swap it over, but not sure how to take apart the middle part with all the yellow trays and fuses or relays. Talking with Blaine he said it has to come apart somehow because they wouldn’t have put all the pins in with it together. He’s going to talk with his worker and figure out how to get it apart.

I tried taking mine apart too, and concluded that it was insert molded. I could be wrong, but I don't think I am. The center circuit traces wouldn't come out, though I got everything else apart.

 

[UKTJ]

Guessing you have had no new news over the Christmas period from Revolution since this post. How long have you been waiting? I bought new gears in November in the Black Friday sale and they have still not been sent. They said they were in stock when I purchased but then said they didn't have the bearings*. I've called them a few times (not cheap when calling from the UK and you get put on hold while they try to find the right person to speak to), but both times was told the bearings would be in "next week", however three weeks on from the last call and the order has still not shipped. I know a lot here are big fans of Revolution, but I'm unimpressed - they know I have contacted them and whay they have told me, they have my email so it wouldn't be too hard to email to explain they do not have the bearings yet.


* I ordered the gears with the Koyo bearings, these show as out of stock currently while the Timken bearing set claims to be in stock. I bought the Koyo for three reasons:
1. In a recent regearing thread somebody ordered gears with the timken bearings, but then hot a mix of bearing sent which ultimately caused a problem as he used a Timken bearing for set up and the final Koyo one was not identical.
2. At that time (September) it was the Timken bearings that seemed to be the problem sourcing,
3. Given 1. and 2. above I saw little point paying a $60 premium for the set with Timken bearings.
It seems when they are short on Timken bearings Revolution will substitute less expensive Koyo bearings, but having accepted an order saying they have Koyo in stock don't do the reverse swap when they don't actuallg have the bearings.

Well, credit where credit is due, I have now had an email from Revolution with an update on my order. They gave me the option to keep waiting or cancel the order, which I think is fair. For now I will keep waiting as it is a while until the company I am using for shipping packs their next container. From the email, Revolution are out of the Koyo bearings, they,ve been on order for a month and a half with no ETA on delivery, but they told me are also out of Timken bearings with no ETA on delivery, or they would have just sent me the Timken ones at no extra cost. So if you are ordering gears (the package with Timken is still not showing as Sold Out when I last looked at the websiteso you could order that) just be aware you may be in for a bit of a wait if they use the same bearings as the ones I need for mine.

 

[JMT]

I finished the loom for the engine and transmission harness. Blaine gave me some good tips for how to secure the loom to the wire just before a connector, how to do T joints, et. al. I almost had to do the entire harness, and yesterday I ran out of harness tape, so I have a few joints to tape up when another roll arrives. Hopefully good for another 100,000 miles. This part of the project was time consuming but fun. I will be replacing all the battery cable from the eyelet at the PDC. I still haven't figured out the PDC broken portion. I can replace the bottom with the one from mine, but the middle section I may have to do a plastic repair.

I put an order in for some more items:

• Auto brake pedal
• Auto starter motor (Mopar) - I'll check the brushes and replace if needed)
• Crank Shaft Pilot Sleeve
• Ignition interlock cable
• Clutch block off plate
• 05-06 unlimited dash wire harness

Once the dash wire harness arrives I'll make sure it's all in order. It needs to be loomed since it's bare. Then I'll decide on my cooler lines, cooler, radiator, and cap. Then I'll start plotting my demise.

 

[PNW_LJ]

I finished the loom for the engine and transmission harness. Blaine gave me some good tips for how to secure the loom to the wire just before a connector, how to do T joints, et. al. I almost had to do the entire harness, and yesterday I ran out of harness tape, so I have a few joints to tape up when another roll arrives. Hopefully good for another 100,000 miles. This part of the project was time consuming but fun.



I put an order in for some more items:

• Auto brake pedal
• Auto starter motor (Mopar) - I'll check the brushes and replace if needed)
• Crank Shaft Pilot Sleeve
• Ignition interlock cable
• Clutch block off plate
• 05-06 unlimited dash wire harness

Once the dash wire harness arrives I'll make sure it's all in order. It needs to be loomed since it's bare. Then I'll start plotting my demise.

I’m curious, why LJ wire harness specifically?

 

[JMT]

I’m curious, why LJ wire harness specifically?

Just because the LJ dash harness what was available at the best price point with all the connectors. The engine and transmission harness is also from an LJ. IIRC, one good thing about the LJ's is they had most of the options (minus lockers LJR). All had AC and many had CC, so you're more likely to get all the connectors you need. I don't have CC, but someone did overlay the CC harness with the LJ engine harness, so it will be possible to add the controls to the steering wheel if I want. Not sure I care to do it on this venture though. So far I've gotten to know my TJ a lot better, but I still have a long way to go. I'm reading the 42rle manual, and I don't understand how it works, but I do understand it has hydraulic, mechanical, and electrical aspects.