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Author Topic: Campsite engine swap  (Read 3490 times)

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Offline Dutch_Jeeper

Campsite engine swap
« on: May 18, 2016, 11:37:13 AM »
So where to begin, i knew my little Go Devil needed some TLC in the form of an overhaul, but by treating her well with good oil and checking the oil level i had hoped to drive it this summer and do the overhaul this winter. Unfortunatly not. On my way to the Dutch Jeep Camp 2016 all of a sudden the oil pressure dropped to zero from 35 followed by the sound of marbles in a metal bucket under load, end of story, stranded 45 kilometers from the event.

Luckily we drove together, my friend had his TJ on a trailer so we switched places and after help arrived to tow my Bantam trailer we continued our journey. When we arrived we unloaded and settled in for the event. Because we volunteer for the club we arrived a week before the event to help with all the preparations needed. It was on a saturday and i spend the sunday helping out and contemplating what to do. On monday morning i started to call around any known supliers and friends if they had a running engine lying around. If we found one we would swap it so i could be driving again by Friday. Luck was on my side when i called Joop Staman who has a company dealing in historic military vehicles and has one of the largest collections in Europe. He had several L134 overhauled engines in stock (and even more goodies beyond imagination, original engines in airtight boxes, overhauled Sherman engines ready to be installed, several tanks of different brands in different stages of restoration, US and German halftracks, aircraft engines, trucks etc. etc. etc. So of i went to get the engine.

This one came from the Hotchkiss factorie stock and recently had a full check up and was ready to run. We also had to get some other parts for my friends TJ and others whoi had already arrived but no time to prepare their Jeeps. It was a 750 kilometer roundtrip before we arrived back at the event site. On tuesday morning we set to work and in no time we had the engine out.

Spend the rest of the day taking the parts of the old engine, cleaning them and while they were out, gave them a coat of paint. By the end of the day the engine was ready to get back in. We used a crane for support, a snatchblock and a winch to haul it out and back in:

Allas, first time in did not go as expected, the engine support plate was the wrong one  :( It had the early style with both brackets facing backwards instead of offset in the CJ3a. Took the engine back out and then went to work on the old engine to get the engine support plate off and on the new engine.

The old timing gear was very worn and damaged not sure where that came from, as far as i could examine the old oil there where no large pieces of steel from somewhere else in the engine, just tiny shavings from most probably the bearings. Both luckily came of pretty easy and without damage, after calling a specialist i was not to happy to tackle the timing gear since according to him it was a matter of "It will come of in one piece or it will not, just pray"

It was hot the entire week and in between helping out for the event and working on the Jeep we were getting pretty tired. And when you are getting tired you make mistakes. Once the engine was in with the correct mounting plate i set to work to install all the other parts.

On wednesday evening we were ready to crank it, nothing but the zoom of a starter not hitting the flywheel???????

Inexperience, the heat and all the other work in between i completely overlooked the flywheel and neglected to compare the flywheels (i got a new with the engine) i then found out there are 3 different flywheels. 97-Tooth flywheel which takes the 10-tooth starter and 124,129-tooth which take the 9-tooth starter.

to be continued
Jeeping - The art of getting dirty and going broke while slowly going nowhere and taking all day to do it

Offline Dutch_Jeeper

Re: Campsite engine swap
« Reply #1 on: May 18, 2016, 11:56:24 AM »
A 97 tooth flywheel does not work with a 9 tooth starter, ok, no problem i'll just get another starter tomorrow. So back to Joop Staman with the old starter and flywheel to see if we could match something up. Unfortunatly we looked at all the different starters he had lying around but there was no way we could make a match. There are differences in the bellhousing, size of the starter tooth shaft, beraings etc. etc. only one solution, get the engine back out and install the old flywheel :( I got a new pilot bearing for it and had it installed, back to the campsite and out came the engine again, switched the flywheel while it was in the hoist, torqued it to specs, lined up the clutch and back in. It was getting pretty late again in between all the other things we had to do, so late thursday night we threw the wrenches had a few beers and went to bed.

The next morning i finished installing everything and around the end of the day we were ready to crank it again. YES, victory without the plugs we cranked the engine untill the oil pressure came up, now all we had to do was set the ignition timing correct. By now the first participants started to arrive and they all came looking how we were progressing, most had followed the story on facebook and had offered help in one way or the other in parts or offers to pick up parts if they could.

1 person in particular who had arrived early became the biggest help. He also drives a flatty and practically knows everything there is to know about the L134. With his thumb he managed to find TDC, then turn the ignition timing and after that the engine came alive after a few cranks of the starter. He timed it on experience and hearing, finaly at around ten o clock in the evening it ran. We secured the radiator with some ropes and made a small victory round accros the campsite. I had the biggest smile of my life ever  ;D ;D

saturday morning i started early and finished the Willy and spend the rest of the weekend slowly and carefully driving it around and had the best Jeep weekend of my life.

Monday evening i made the 260 kilometer drive back home, not exceeding 30-35 mph it was a perfect run in trip for the engine. All that is left to do is change the oil and adjust the valves and take it easy for another few hundred kilometers to run it in properly.

I have many friends to thank to make it possible and motivate me to finish it, learned alot but would do it again in a heartbeat, which will not be neccesary anytime soon with the new heart for the Jeep  ;D ;D

I even got second place in the concours d'elegance  ;D :)

Jeeping - The art of getting dirty and going broke while slowly going nowhere and taking all day to do it

Offline RICKG

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Re: Campsite engine swap
« Reply #2 on: May 18, 2016, 02:10:16 PM »
OUTSTANDING! [smiley=thumbup.gif]

Offline aboyandhisdog

Re: Campsite engine swap
« Reply #3 on: May 18, 2016, 02:36:20 PM »
Very impressive, DJ!  Hope some day you get a chance to visit here for the Fall Color Tour or the Black Hills Run - you'll fit right in!

Offline johnrb3b

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Re: Campsite engine swap
« Reply #4 on: May 18, 2016, 02:50:44 PM »
Ah the fun of old Jeeps.
Don't we all love it?
Nice that there's a happy ending to the story.
1946 2A - - - 1949 me - older than most of my Jeeps
1954 3B - - - 1957 Wagon - - - 2010 4-door JK
past Jeeps ---> '54 3B - no tub --- '59 3B - no engine
past addiction - VW ---> '69 bus --- '70 camper

Offline Kirkski

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Re: Campsite engine swap
« Reply #5 on: May 19, 2016, 05:13:53 PM »
Great story and pics, glad it turned out well!
'52 CJ-3A

Offline Ryan_M

Re: Campsite engine swap
« Reply #6 on: May 20, 2016, 06:11:29 AM »
Talk about not giving up. Way to battle through it!
'49 CJ3A
'51 CJ3A
'42 Willys MB-T
'47 Bantam T3-C
'46 2A
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East Coast Wi

Offline Oilleaker1

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Re: Campsite engine swap
« Reply #7 on: May 20, 2016, 07:56:10 AM »
Impressive. You also have hands on experience that is not found in books. Well done. I enjoyed following your story. John