Step By Step TDI Swap - Part 4: Engine, Transmission Mounts, and Driveshafts

On this installment of the TDI XJ engine swap we bring the BEEF. Shafts so sturdy Crossfit athletes are pressing them instead of plates, a heavy duty transmission mount and custom crossmember that will make your stock stuff wilt, and of course welding up the TD Conversions engine mounts (they've got plenty of certified lean beef too). We'll talk about where to start with welding all that up and the fabrication process, measuring for those driveshafts, and checking off another big step in the project.
Part 1: • How can a 1.9L replace...
Part2: • Step By Step TDI Swap ...
Part3: • Step By Step TDI Swap ...
Part 4: • Step By Step TDI Swap ...
Part 5: • Step By Step TDI Swap ...
Part 6: • Step By Step TDI Swap ...
Part 7: • Step By Step TDI Swap ...
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This product is meant for entertainment purposes only. Your mileage may vary. Do not try this at home. Void where prohibited. Some assembly required. For off-road use only. Slippery when wet. Batteries not included. Do not use while operating a motor vehicle, heavy equipment, cherokee XJ, wrangler TJ, wrangler JK, or any Jeep vehicle, especially the newer Fiat ones. How-to videos may be too intense for some viewers and children under 30 years of age. Please remain seated until the 4x4 ride has come to a complete stop. Studies have shown viewing these videos causes increased cancer risks in laboratory test people. I am not a professional, I have no training, I'm not even particularly good at horse whispering. Don't believe everything that you know. Please keep your hands in the vehicle at all times. Do not tap on glass. Do not eat anything that has been on the floor for more than 3 days. Keep your hands to yourself. Not to be taken internally. Reproduction strictly prohibited. Driver does not carry cash. Objects in Bleepinjeep mirrors may be farther than they appear.
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[@jacobkelley257]

Hey I don't know how editing works on this channel, I assume each of you edit your own. But just a tip, make the music quieter when you talk. Sometimes had to rewind to catch what you said. Awesome video though. I plan to have some Adams driveshafts in a future project

[@ewingfox6459]

Another great video thank you! Sorting out a crossmember on the bench is quite a challenge. I took a different approach starting with hanging the engine/trans in the jeep, using a post jack to determine my desired manifold angle (ok, to be honest, making sure my rad/fan angle was kosher) and that my pinion angles weren't going to be impossible. Then, I measured and did some dirty CAD ( Sooty Cardboard Aided Design) in place to develop the new crossmember, with centrering bolts ( allthread with ends turned into spikes) to define critical mounting points that were non-negotiable. I like your use of square stock, I had a pile of DOM tube kicking around which looked great in the end but was a pita to work with. Because I wasn't sold on my final engine/trans disposition, I also pre-fabbed a number of 1/16" shim plates for the GM rubber trans mount I chose to use (for spousal approval reasons) Great fun as always to watch your thought processes. Good to see you support an awesome company like Adams, their customer support is second to none!

[@zeepkiki98]

not sure why these videos get dislikes, buncha wusses not liking an XJ without a 4.0 in it I guess haha

[@DRTJon]

HenryH yeah the first 10 minutes it was up had 7 dislikes already. Not sure why that is. haters just gotta hate I suppose

[@MrMrsregor]

@@RDCM1008 haha, you gave it a thumbs down cause you think the stock sheet metal crossmember is better than this 1/4" think crossmember .?. lol

[@drubradley8821]

I didn't know "Skreech" from Saved by the bell, played with Jeeps... How cool is that... I bet Zach has a Rubicon...

[@moedalgarny]

10/10 intro 😂

[@kylelewis3504]

20 seconds in and I had to pause to say I love this intro 😂😂 this is probably one of my favorite builds so far! Glad to see they added you to the team can't wait to see more!

[@DRTJon]

Kyle Lewis thank you my man! Super encouraging words. I had this intro a lot longer but by the time you got to any meat and potato’s it was 3 minutes in haha probably best I made it a little more “fit n trim” 😬

[@kylelewis3504]

I also really enjoy the more detailed videos I feel like I could actually reference the videos to do stuff rather than just a quick time lapsed video! Keep up the good work!

[@GoatOffroad]

Can we compare my Crossfit 💪 guns with yours!! We’ll race pulling our XJ’s!! 😂 If I win, can I be a Bleepin’ Girl!?!? 😄 Love all y’all! Y’all never fail to teach me something new! ❤️🐞

[@kylelewis3504]

Subbed to your channel can't wait to watch those rust repair videos! Anytime I find someone with xj how-to's it's an instant sub!

[@DRTJon]

Ill have to check with Matt...but you’ve got my my vote 😎👍🏼👍🏼

[@GoatOffroad]

Kyle Lewis - yeah! My first rust repair video is awful! I’ve almost deleted it; it was before I had much experience, and we had zero lighting. My newest rust video is a lot better!!! Thank you for subscribing! ❤️🐞

[@GoatOffroad]

Jon BleepinJeep - Thank you Jon! ❤️🐞

[@MegaModelMan]

great video! i love this build. however it was a little hard to hear you with the background music

[@aidannicholas9965]

Is this still ongoing? When’s part 5 coming? 🙂 Interesting swap wanna see it finished.

[@DRTJon]

Follow the playlist "Project Spool Bus" to ensure you're seeing the full list of videos available for this project

[@shlarticus32]

Thanks for documenting all this, really gonna help when I start my TDI swap. We are patiently waiting on part 5!

[@bobr7773]

I really like your series. I want a reasonable trail capable 4x4. I want to tow a small travel trailer so I don’t want a lot of lift/decreased stability. Could I clock the TDI, use the Passat AC bracket and clear the differential/axle with minimal lift? My gas Chevy 2500 HS kills my wallet at the pump.

[@EvanMoon]

Why don’t these aftermarket pieces put themselves on? So inconsiderate

[@Roboticdoughbull3k]

Gotta lose the background music bro can't hear w it rolling. Good information however ty.

[@DRTJon]

Kevin Doble will remedy next time thanks. On my reference speakers in the edit station it sounds fine but on a phone speaker it’s pretty tough so I understand. Thanks for the feedback

[@rabblepeasant2676]

Stop the background music!!! If your talking i want to listen to you not some dumb music.

[@kylelewis3504]

I prefer it to just monotone boring talk personally gives a little bit of a lively feel even though it's not my taste in music ☺️

[@keeganlayes5903]

Are you using a dana 300 transfer case with a flip kit and a doubler in front of it???

[@DRTJon]

Keegan Layes correct

[@keeganlayes5903]

@@DRTJon going to do the same for my cherokee. Any pointers in doing that or are you going to make a video too??

[@DRTJon]

Keegan Layes it’s a nice setup for me so far. Fits really well and I could actually swap it out for a 231 with SYE its only 1/2” different and yokes are exact same. I’m not sure if I will do a video on it yet

[@keeganlayes5903]

@@DRTJon it would be nice to have a video of it. I've been trying to search and make a parts list but I dont know what's all involved into doing that set up. Would be nice to have a guide line. I do like Nates set up with the atlas but I like the d300 cause of its jeep related history. Plus low gear ratio for the trails.

[@theramblingjeeper6929]

Any photos on how you welded the mounts?

[@nathanp5507]

I thought TDconversions sells ready made mounts? Why did you have to weld them. Also how do I know which way to clock the engine. Wouldn't that be standard on all XJ?

[@danhambrick6331]

Why didnt you go with 1350 drive shafts?

[@DRTJon]

Dan Hambrick Just couldn’t swing that level of investment at this point

[@psyfluffybunny]

For my 305 4l60e swap I used 4ft of 2x6 3/16 steel tubing ($55). Cut a piece off the end where the crossmemeber looked centered on both sides and welded that extra piece on top for the transmission mount (trans pan wouldnt clear crossmemeber). Also i tapped out the 3rd hole on both sides. Reamers made drilling holes very precise and easy

[@michaelvillalpando8601]

I have a 91 jeep cherokee what should I get for a lift just want to do some basic crawling

[@tylermartin6683]

Matt or any one in here lol I need your help on information on a 249 to 242 swap if you have time

[@47kb8]

I don't know if you answered this yet, but are you going to mention how the electronics were blended. Are you going to show a followup to how she has been going since completion. I am interested in the mileage comparison from before to after.

[@DRTJon]

Electrical is part 7. We'll wrap it up with a part 8 which will talk about performance and economy!

[@joenorris449]

Instead of cutting and grinding why not just change the direction of the bolt; could not tell from the video but perhaps the nut end toward the bracket instead of the bolt head would have worked better?

[@DRTJon]

Joe Norris being a nylon lock nut it offered much less clearance the other way around

[@sidewithwerewolves]

I'm wondering if it's easier for wrangler owners to put in a 3.0l ecodiesel or the 2.8l duramax which is the same as the vm motori crd used by diesel jeeps internationally.

[@DRTJon]

sidewithwerewolves that I don’t know but I’m sure those engines are not inexpensive or easy to transplant though of course where there’s a will (and a fat wallet) there’s a way

[@SamSam-ke9zy]

Ironman 4x4 Fab may take 6 weeks for you to get your parts. Also, their directions might not be right. So I found when I ordered some steering parts.

[@DRTJon]

I know they've had trouble keeping steering kits in stock in the past. I also know I've dealt with these kind of delays (or much worse) many times over on this build, and it is frustrating. I found Ironman 4x4 Fab to be very responsive. I won't name names but I can't say the same for some others I wish I had not spent my dollars with. To be fair most of these guys are small shops focusing on quality and trying to keep up with demand, so customer service can be a real challenge in the busy times.

[@devinhausauer7660]

I’d like to keep my auto trans and like to know how I could swap the tdi and keep the auto

[@DRTJon]

Join the TDI swapped trucks group on facebook there are a few people on there who have done it with the AW4 auto

[@MinecraftMgalekgolo]

Do you project an increase in TDI prices because of all the recent hype over these swaps into Jeeps?

[@DRTJon]

Myles Gregory nation wide I don’t think it’s that big of a thing yet or growing that rapidly. But logically I can’t say no: they’re not making any more of them so supply is decreasing and demand, Regardless of how slow or fast, is increasing. My personal opinion is it will be a long time before the prices on them would anywhere close to double, and the engine cost is already not the most expensive portion of the swap.

[@Adam-vc1xl]

I am waiting for someone to talk about how to put a tdi and a auto together

[@DRTJon]

The mechanical coupling of it will be the same, just with a flex plate and torque converter instead of clutch and flywheel. From discussions I've had, you can run a full manual shifter pretty easily, or mock up a throttle position sensor. Join the group TDI Swapped Trucks on Facebook, tons of knowledgable people and info there!

[@colinlogan4879]

When is the next vid coming out

[@MrRmga420]

Double cardan not cv.

[@njsurf1973]

Any updates?

[@DOCTOR_KIA]

Have you gotten the A/C to work ?

[@DRTJon]

See Part 6 :-)

[@jodyspencer433]

Will it cruise 80 on the interstate?

[@DRTJon]

Jody Spencer stock turbo and nozzles yeah it would, but much more easily with upgraded nozzles and I assume once I get the turbo upgrade too it will really be effortless.

[@MattyGgardneR]

what torque did you tighten the transmission mount crossbolt to?

[@DRTJon]

I believe it was gütentite

[@MattyGgardneR]

I'm running a stinkyfab t mount with poly bushings on one of our XJ's... Worried about increased dental visits up here in Montana ;)

[@DRTJon]

@@MattyGgardneR hahahahaha yes! This is NOT polyurethane, it's a much softer rubber, similar to a control arm bushing. It took about 500 miles before it was broken in. Vibrations felt were not bad but noise transfer has gone way down. The bolt has a nylon lock nut so it does not need to be torqued down heavily, just definitely don't want it to be sloppy

[@codymoncrief8478]

4.2 > 4.0

[@jimforsyth2.]

That's not a OE mount

[@DRTJon]

Frederick Forsyth what’s not?

[@crayfishroll]

What tcase are you running?

[@DRTJon]

crayfishroll flipped Dana 300 with Strongbox doubler. 7.16:1 crawl ratio in low-low. It’s a nice setup I like it so far. The NP231 with SYE could actually swap right in the measurements for shafts would be within 1/2”

[@crayfishroll]

@@DRTJon that's a sic setup I just caught glimpse of it. I'm stil going to run my np231 for a while but that was an option I looked at before.

[@renegade4wd12]

What happened to Nate?

[@TheTacticalHouse]

Johnathan Lott waiting on that overland build!

[@DRTJon]

He made the decision to leave the channel to create his own separate channel and build his own brand

[@renegade4wd12]

Jon BleepinJeep Damn that sucks. Hope he does well.

[@harlemwilliams5663]

What is ur mpg with the tdi swap in the xj?

[@DRTJon]

first full tank was 31.5 MPG. I did a partial fill up after that, then was on my next full tank on a longer trip and the turbo bearings started to go out, so it's down for turbo replacement now. I have more miles on that tank with more showing on the gauge than when I filled up when calculating the 31.5 MPG so I expect it will be somewhere between 32 and 36 MPG regularly