Scout II 4.0 w/ hydraulic clutch swap

[Mt Hood Carl]

I found a clevis rod end that fit the arm and adapted it to the TJ pushrod.

[Mt Hood Carl]

Even with the adapter, the new parts are 30lbs lighter than those being replaced.

[Mt Hood Carl]

The hydraulic slave fit both the Scout trans tunnel and the T-18 like it was meant to be there.

[Mt Hood Carl]

The master cylinder location is pretty close to the intake manifold. I used a newer intake to give more clearance. There are other posts here on BP showing alternate ways to mount a hydraulic master. I don’t know if the location I used would work with an SV. In my case I replaced the bracket that comes with the Jeep master cylinder with a stout custom bracket. It bolts thru the firewall directly to the support structure for the pedal assembly. Zero firewall deflection.

[Mt Hood Carl]

I am using an earlier Jeep/Dodge reed switch type VSS with speedo cable pass through. This was a bit tricky because the’94 PCM supplies 8VDC to the sensors but expects a 5VDC square wave from the VSS. I rigged up a pull down circuit on the VSS output. I need to redo this to keep it clean and cool so it won’t die on me.

[Mt Hood Carl]

I found that the electric fuel pump from a Fox body Mustang is almost a drop-in replacement for the IH sending unit in a 19gal tank. The pump pick up location is absolutely perfect- same for/aft as stock sending unit and just a hair off the bottom of the tank. For the time being I have no fuel gauge. It never worked that well anyway. Both lines exit the pump toward the left side. The filter is at the left-front corner above the tank. The filter has no room to move so it is not even clamped down. I ran steel lines above the left frame rail to the engine bay. I used OEM style fuel injection connections on nylon jumpers. Pump wires were fished through the right frame rail. I took pics but now I can’t seem to find them.

[Mt Hood Carl]

I spliced in the engine management from a 94 YJ. The PCM is on left inner fender, PDC on the right below the windshield washer bottle. The battery was relocated to right side. The fan and accessories are also YJ. The fan shroud is Ford explorer, rotated 90 degrees and modified a bit. The air filter and intake tube are from a TJ- you can see in the pic some adjustments are still needed for a better fit.

[Mt Hood Carl]

Driving impressions: The 4.0 runs fantastic. Starts right up and can be driven without warm up. I am really happy with the clutch too. It has a light feel and seems to engage at about the right point. And the shifter works way better now since I rebuilt the trans.

Special thanks: I had help on the more significant machining steps. The CNC milling on the thick adapter piece was done by Bill MacCracken in Tigard, OR. See more examples of his work at http://www.motovecchio.com. The thin adapter piece was cut on a water jet by Aquila Glass in Portland, OR. Both resources were willing to take on my small job at a reasonable cost. Bill worked from my 3D CAD geometry. The water jetting was done from a 2D profile generated from the CAD model.

What’s left to do: I may post some updates when I get around to some remaining details. One thing I am excited about is the tachometer I got on ebay for $10. It is a brand new part for a 94 YJ so it is plug and play with my PCM. For the engine break in, I just taped the tach to the dash pad. It worked perfectly. I just need to make a permanent home for it in the dash.

In the future I would like to try the same adapter to swap in a 4200 Vortec using a Hummer bellhousing. A little extra work would be required in custom motor mounts and oil pan. Maybe someone else wants to try it?

[truck mechanic]

oh so very cool! now you got me thinking about doing the same in my 72!

[surfnturf]

impressive