clutch/flywheel for a 3.4 into a TJ wrangler?

[js35]

Hey guys, awesome site you have here, already learned alot just browsing around. I'm in the middle of putting a 94 3.4l camero engine in a 97 TJ wrangler, I am replacing the 2.5l four banger, not the usual old 2.8l in a XJ cherokee. I'm having a little trouble figuring out the clutch/flywheel combo, I have the AX5 5 speed trans so the 3.4l bolts up, but something is different. I posted a thread on the wrangler forums but got little help, not much 60degree or AX5 love there. The 2.5 has a thick flywheel, I bought an early 90's s10 flywheel but it puts the flywheel surface back torwards the engine/trans mounting surface about 10mm, I haven't bolted it up yet but I assume that this will not allow the clutch to release properly. The clutch disk and pressure plate are identical to the old XJ 2.8l, so I figured the key was to get the old XJ 2.8l cherokee flywheel and have it neutral balanced, I could not find one of these anywhere local and no one could order one, finally found one on amazon and ordered it. http://www.amazon.com/gp/product/B00...ls_o00_s00_i00
But now that I have found this site and this thread:http://60degreev6.com/forum/showthre...highlight=jeep I'm not so sure it will work either. I looks just like the newer s10 flywheel I have. Not sure if clutch fork or throw out bearing is different or what, any ideas? Thanks in adavance.

Here is a pic of the s10 flywheel vs the 2.5l(right)

[js35]

I'm think about checking out a camaro flywheel, cant seem to get one locally without ordering it, anyone got a side shot of one?

[Barry]

I dont want to clutter this thread so ill keep it short, but heres some measurements I took on flywheels.



Left is a fwd beretta/cavalier v6 flywheel, and a spec stage 3 clutch. On the right is a 88 camaro 3.1 flywheel with stock replacement LuK clutch.

From crankshaft to clutch fingers is 1.250~ inches deeper on the camaro.

SO, make a spacer for the fork? Sounds pretty easy.... but theres 2 issues. With a spacer that deep, the bearing wont ride on the input shaft tube anymore and will be on the splines. Secondly, the clutch disk will be 3/4 on the splines, and 1/4 on the pilot bearing area. The pilot bearing stub goes into the crank about 3/8"

Heres my plan:
Machine bellhousing face to motor 1/4", and bellhousing face to trans another 1/4". That buys me a half inch, and gets the disk fully on the splines. Likely I will have to cut a little off the input shaft stub. Then a 3/4" spacer for the fork to get the bearing out to where it needs to be. If its not fully on the tube when clutch is open, then ill extend that tube.
I am using toyota supra huydraulics so that will all be custom anyway.

Camaro vs Fwd. I think FWD is close to s10 I think. I wrote this a while ago. I ended up using the camaro flywheel, which is bigger than the fwd flywheel, so I made a spacer for the starter.

[js35]

thanks for the info, I bolted on the camaro flywheel tonight, it sits about 10mm to high, but I figured it was better than too low and I guess I could get it machined down a bit. I thought that it would put too much pressure on the release bearing and possibly make it slip. The jeep clutch bolted up fine so I bolted it to the trans in the truck and turned the engine over by hand. I could hear and feel the fingers moving and it felt good but the clutch would not release. In gear it would turn the wheels no matter what, If I applied the brakes the engine would just stop turning with the clutch on the floor, I dunno, got pissed and left it in the garage but tomorrow I'm gonna yank the motor back out and see what I got.

[geoffinbc]

Is the hydraulic clutch been bled or confirmed working before the new flywheel? I would not machine the flywheel that much in order to make it work. Serious warpage and cracking may occur.

It would probably be a better idea to use the S-10 clutch and spacer behind the flywheel. Advanced Adapters may have better info on how to make it all work. They do a lot of Jeep work and would know an AX5 and AX15 better than anyone.

[js35]

yanked it back out tonight, camero flywheel was too long causing the release bearing tube to smash the disk into the flywheel, no damage done, it just kept the clutch applied to the flywheel. So I tried the S10 flywheel just to do it and spaced out the clutch fork pivot ball with a few washers. put it back in, cranked by hand with it in gear and clutch works great, even releases about midway. Now I'm on to the mount brackets, any good links on making them? I can weld and measure, but never made more than one mount or on a RWD vehicle. I agree about the flywheel machining, too thin. Advanced adapters was zero help, the chuckled and said "we're usually pulling those motors out, not putting them in".

[js35]

hey guys, the swap has been on the road for a couple months now, doing great, if anyone is attempting the same, feel free to ask any questions.

[geoffinbc]

Sounds good. I bet you get a lot of weird looks from other Jeep guys. Got Pics?