DanB98TJ and I are in the process of swapping my manual to an auto ('98 TJ, 4.0). We have the auto transmission bolted in, but when we tighten the bellhousing bolts the engine can't be turned over (using wrench on crankshaft bolt). If we loosen the bellhousing bolts, the engine can be turned.

Any ideas?

Did you make sure the torque converter was engaged with the front pump before you bolted everything togoether? Sounds like the problem to me. Loosen the bellhousing bolts and take all of the torque converter bolts out. While pushing on the torque converter spin it. It should engage with the front pump and drop in about another 3/4" or so. Then you can bolt everything back together. Either that or the front portion of the torque converter is hitting the pilot bearing if its still there.

The converter is fully engaged in the pump, but it appears the pilot is the issue. We pulled the pilot bearing, but there is still some kind of spacer ring that the bearing fit into. That has to come out...somehow. There isn't enough room to get a set of puller jaws between the "ring" and the crankshaft (only about 1/16").

I've never seen anything like this before - what kind of weird $**t did DC do?:mad:

Here is a link to the photo - can't link to Webshots::mad:

http://community.webshots.com/photo/13956804/45014385fZYjiB

Any ideas how to get this b@stard out of there????

I just went through the same thing, you have to chisel it out. It is soft metal and then everything will fit fine.

BlueYJ

Yep !

Well, we did manage to get it out Sunday morning....after an hour or so with a big air chisel. Had to cut through top and bottom and pull it out in two pieces. Whoever came up with this design should be beaten to death with a driveshaft.:mad:

I also found out you don't want to use air tools with CO2 in a confined space.....:eek:

We weren't able to get everything finished up this weekend - came across a few more parts that were different between AT and MT, so they're on order. Hopefully everything will come in and we can get the Jeep back on the road.....er, off the road.;)

the other thing to caution you on is the crank sensor. I dont remember if 99 uses the same crank sensor as your manual. I put a 2k 4spd auto out of a TJ in my 95 and the crank sensors are completely diffrerent. I got the crank sensor for the 2k and wired it like the 95 and it wouldnt start. Found out the only difference between the CS's where the volts going to each one. The 95 was 8 volts vs the 2k at 5volts why this made a difference I dont know. Thank god for JB Weld, hacked the old mounting bracket off the 95 crank sensor hand held it down in the hole and the jeep started right up. So appoxyed the bracket in place and bolted it in and wala the jeep runs. But your right the frigen transfer case shifter is completely different so that is the next thing on the list to do. Mine has the lock up torque converter for 4th gear and I love it with the 4.88's. Good luck.

BlueYJ

I bought a new CPS to use. For a '98 TJ (which mine is), automatic. The FSm recommended replacing it if the tranny were removed without removing the CPS first. The donor tranny still had the CPS installed, so I knew that it wasn't removed first ;)



:)
Fred