Topic: Hacked UP 97' TJ 2.5L - Previous Owner

[MakoML]

 

No compression in #1 and #2, it over heated with the gauge going straight to 260, no warning, started knocking and clanging, and water pump weep was running like a tap.  Also could swear the CAT was plugged up and rattling So I thought I should make sure it was just a blown head gasket before replacing the water pump etc.................. replaced head gasket,  Really great compression in #3 and #4,  ZERO in #1 and #2.............. I was afraid of that, as there were also missing 3 of the 4 exhaust manifold bolts/studs  telling me someone had been in there before. .................. and a big crack in the manifold.

So I started looking at the situation and decided I should yank it out and take a deeper look before spending another dime on it.   In the process I discovered crank pulley bolt is loose, the accessory mounts are missing bolts and nuts etc.    I pulled the exhaust to find the CAT was gutted.  THe rear O2 plug is gone and sensor wiring is hanging there.  No check engine light either..... meaning they killed the LIGHT! I get to the wiring and am looking for the distributor wire plug................. I see a ball of Electrical tape where it should be.... great.

Un wrap the tape to find cut wires that had been TWISTED together and taped.  UN FRIGGIN REAL.

I had decided before I took it apart that if this stock set-up was going to cost more than $300 in parts and machine work, it was getting a V-8 swap............sadly,  I think this 2.5L is done for in my jeep.

[lax22]

sorry to hear all that. Sounds like the PO was no good to that poor rig. 4.3L swap time!

[Torch_Ind]

one how good did you look over this jeep when you bough it? missing bolts and cracked manifold and it shouldn't have ran all that well having 2 dead cylinders?

#2 when you did the head gaskets did you check the valves or cylinder sleeves?


sucks about the luck dude

what did you pay for it?

[sharpxmen]

i can't see how you can have zero compression on cyl 1 and 2 other than broken rocker arms or misplaced/bent/missing pushrods (even with broken rings you would still get some compression) - was the old cyl head gasket busted when you replaced it? sounds about right from what you describe so i would take the valve cover off and turn the engine by hand to make sure the valves are opening and closing

[Torch_Ind]

i can't see how you can have zero compression on cyl 1 and 2 other than broken rocker arms or misplaced/bent/missing pushrods (even with broken rings you would still get some compression) - was the old cyl head gasket busted when you replaced it? sounds about right from what you describe so i would take the valve cover off and turn the engine by hand to make sure the valves are opening and closing

I feel the story is lacking some details in areas. 

you also state the cat was plug solid but when you pulled the exhaust you found the cat was gutted? 

a lot of the story doesn't add up to me. 

I would ask you try to fix up the story some. I understand you may have just needed to vent a bit with the situation. 


hope you figure it out

[MakoML]

I said I thought the cat was plugging up................  do to the horrid mpg, lack of power and rattling.................. obviously it was not the cat after I started ripping this thing apart and found it was  gutted. 

I paid $2500 for it.  It ran, had zero rust, and I thought it makes a good budget build rig.  I didn't look it over much at all.  I asked the P.O if any engine work had been done, any mods, etc.   They said no.  They lied.  I still would have bought it if they had been honest.  I knew the AX5 had the typical 5th gear broken snap ring issue but that is an easy fix. 

I have disassembled the engine.  The pistons in #1 and #2 have been wearing on the cylinder walls,  the rings are ground down and- worn flush with the piston on one side. The rings do not move in the grooves at all.  The walls are all gouged up. I do not think going .060 over will clean them up.   The rod bearings are not too bad. The crank looks okay.

I checked the heads before I replaced the head gasket,  and it looked to me like the head had been recently overhauled. I could see some "issues" with the cylinder walls, but decided to see if the gasket would at least get it running again for awhile.  No dice.


I also found chunks of gear in the tranny oil when I drained it. 

So, like I said, I think the 2.5L is done in this jeep.   I'm going to take the block, crank and rods to the machine shop monday are see what they think.  I am looking at various V8 swaps, and  leaning toward the Ford 302W - 5.0 HO swap.   Now I have to decide on what tranny I want to use,  because Ford trannys are less than stellar in my experience.  I also just came across a FRESHLY REBUILT, plastic wrapped and on a pallet,  351W short block from 79' for $100 from a guy at work that I am looking into making work. 

I'm not a rock crawler or mudder............ I use my jeeps to take me places that are too far to hike and where cars and other stock 4x4 vehicles don't dare to go  on National Forest 4x4 roads and jeep trails when not on pavement.  One of the first mods I had planned was increasing the gas  capacity in the stock tank.  Other than that I out a simple 2" Procomp spring lift with BDS shocks on it, and Moab wheels with 285/75/16 tires which are too big for those  rims back spacing without spacers, lots of rubbing and binding going on there.  Will be dropping back to 32's or 31's after the jeep runs again.

[Torch_Ind]

Well I hope your budget build goes better than it has so far! 

[sharpxmen]

good luck with the swap - keep us posted, sorry to hear about the mess in there.

[MakoML]

I took the block, crank, head to the machine shop yesterday.   He thinks he can clean it up at .030 over and just polish the crank.  So we'll see.  The head he thinks could be cracked but we'll find out when he calls.

I tore into the AX-5 yesterday to see about sliding the 5th gear back on the shaft and locking it in place with the snap ring.   I have a problem, it is obvious someone has taken the case halves apart before.  I picked up all this with my magnet from the drain area.   So I thought I should look at all the gears and removed the front case half.  There is the broken snap ring for 5th gear,  and also a bunch of chunks of broken GEAR teeth.  Problem is I can't find any broken gears in the thing.  So someone fixed it without cleaning up the FOD left behind before putting the case back on?   It would fit with the P.O. hack techniques but really?

[aka-justin]

Wow.  Sorry man.

[jfrabat]

All I can say is that even as lousy a mechanic as I am, I am still a better one than the one who worked on THAT Jeep!

[MakoML]

My Machine Shop guy cleaned up the block at .030 and turned the crank 10/10.  He's surfacing the head and doing a valve job.  I guess I'll hold off on a swap for now and get it back on the road. 

Does anyone know what the wires to the distributor are for, and where I can find a replacement plug for it? 

[sharpxmen]

My Machine Shop guy cleaned up the block at .030 and turned the crank 10/10.  He's surfacing the head and doing a valve job.  I guess I'll hold off on a swap for now and get it back on the road. 

Does anyone know what the wires to the distributor are for, and where I can find a replacement plug for it? 

the wires on the distributor are the cam position sensor - you can use any 2 prong connector, not sure where you can find a replacement other than the junkyard (i'm sure there are out there just don't know what to look for)

[jfrabat]

I replaced my cam position sensor while in Panama; I found it at a parts store, Crown brand.