Novak Conversions Jeep Wrangler TJ engine mounts

So, it's happening! The build begins.

m.rezo

Member
Original poster
Supporting Member
Joined
Apr 28, 2021
Messages
28
Location
Superior, CO
Excited to say that I'm the proud owner of a new to me 2001 TJ Sport 5 speed. I've always wanted a Jeep, but somehow, never managed to commit to buying one until now. I've been a long time VW fanboy owning several of them over the years, meticulously adding modifications that add to the overall driving experience over strict HP performance. Looking forward to applying that same doctrine with the TJ (let's face it, there aren't much performance gains to be made anyways) and creating an exceptional rig tailored to suit my needs that handles great both on road and off.

After looking for about two months, I found a rust free TJ that was posted online one morning at a dealer that I had just visited the day before looking at a high mileage JK Rubicon 3.8L. They said they were still prepping the TJ and were getting the listing ready. Well, as luck would have it, the listing only lasted about 30 mins. I made my way over (again), took a good look at everything as best I could. It was clean. Real clean. I ended up leaving with the keys an hour later.

The TJ has some "tasteful" modifications and a recent service done at the 100k mark (timing chain, clutch, throw out bearing, water pump, belts). I bought it with 127k as it sits in the picture below with all the mods listed. I appreciate the little details in the previous owner's build. For instance, the upgraded sound bar and double din radio, Bushwacker fenders with LED blinkers, Bilstein 5100's, and a DIY sound insulation install. All neatly installed with wires loomed and tucked, sound mats cut perfectly to the tub, etc... They cared for the TJ, did things methodically, and that in itself, gave me enough confidence to know that this was the Jeep for me.

So without further ado, here she is the weekend after I got her!

IMG_0639.jpeg


Mods that came with the Jeep

Driveline
  • Dana 30 front with 4.88 gears and Power Trax Grip Pro Limited slip differential
  • Dana 44 rear with 4.88 gears and Power Trax No Slip Locker
  • Slip Yoke Eliminator Kit mounted at rear of transfer case
    • I had to have the rear driveshaft shortened just a bit as it seemed a bit too long
Suspension
  • 4" lift (unknown). Has 2" spacers at the top of the front coils. Seems like the kit was probably being pieced together over time
  • JKS front quick disconnect sway bar links
  • JKS front lower control arms
  • JKS rear lower control arms
  • Bilstein 5100 shocks
Wheels and Tires
  • 35x12.5x15 Mickey Thompson Baja MTZ P3
  • American Racing 15" steelies
Engine
  • Edge throttle body spacer
  • K&N air filter
  • Hooker black heart header
  • Banks monster exhaust
Bumpers and Protection
  • Front bumper stubby mod
  • Front grill guard (unknown mfg)
  • Bushwacker fenders with LED blinker and DLR
  • Rock guard (unknown mfg)
  • Trailer hitch
  • OR-Fab rear tire carrier
Lights
  • KC Windshield mounted ditch lights
Sound
  • Pioneer Double Din Radio
  • Upgraded sound bar with Kicker speakers
  • Kicker speakers up front
  • Subwoofer delete!!!! LOL. (This was the one thing I think he took with him unfortunately)
  • Sound deadening / insulation with foil bubble reflective barrier (primarily used in RVs)

I've had to get used to driving a manual with auto lockers. That's been an experience for sure! I don't daily drive the rig. I mainly use it for quick errands here and there and take her straight to the trail head. I'm still getting used to the combination of pedal feel + added backlash due to the lockers + engagement/disengagement points upon acceleration and coasting. It's been fun. I learned very quick to be careful driving on a snowy hillside trail. :oops:

Not going to lie, she rides like a bucking bronco on the road sometimes going up driveways, going over bumps, or accelerating in turns (also learned not to do that with lockers). But that's just the way she rides for now. I can't help but smile every time I take her for a spin. I would like to smooth out the ride in due time and am leaning toward the full 4" Currie short arm kit in the future unless folks have other recommendations on the forums. I'm all ears.

On the trail, she does amazing! Made it through the Iron Clads trail just outside Boulder no sweat. Had a great time. Plenty of clearance. The lockers really shined there. Felt like she was in her element, though, it was still really bouncy at times.

Well, onto the build!

First course of action was removing that K&N filter!!!!

It's gone. Went with a Wix paper filter. May be switching to AC Delco moving forward based on threads in this forum. Keeping the K&N filter just in case. I did notice a very slight decrease in low end power after replacing the K&N with a paper filter as well as a slightly decrease in depth of tone in my exhaust. All non-scientific. With the K&N filter in place, I was able to slowly release the clutch and easily climb over the hump in my short driveway to get into the garage without hitting the gas. No shudder, just smooth power. I was actually quite impressed with the Jeep's ability to do that. With the paper filter, when I approach the same hump and release the clutch, the engine struggles a bit and RPMs dive low enough that it triggers the "hit the gas so you don't kill the engine" reflex. It'll eventually make it without the gas, but just shudders a bit more.

Next were fluids!
  • Redline MTL for the NV3550. It helped quiet up the trans a bit. Shifting is about the same as before but get's smoother quicker, if that makes sense. Doesn't take as long to warm up I suppose
  • Brake fluid flush
  • Valvoline Synthetic Blend motor oil on sale! w00t! Haven't decided on a long term oil for the 4.0 yet. Recommendations welcome.
  • Purolator One filter
I'll be working on the rest of the fluids next and deleting a few items (bumper guard and rock guards) as their not my style and replacing with something that can handle an aggressive hit or two . Other than that, she'll stay like this for the immediate future though I plan to do a few other small-ish things. I want to be hitting the trails and learning the rig before I start removing anything significant where she'll be on jack stands for a couple a weeks.
 
Last edited:
Welcome to the forum!

You got a good start on a build. And a good looking rig to rig to build up!

Good luck with her, and get your wallet ready for emptying! 🤣
 
Welcome to the mix. Jeeps are a addictive hobby but they offer a lot of return for what you put into them.

Man you scored on that TJ. Those are some nice mods to be starting from and is a REALLY nice base to build from.
 
Update: after taking the Jeep to a few moderate trails in the Boulder area, I decided to go on a camping trip at Holy Cross. The trail has some pretty technical sections and proved to find all the weak points in my rig. The result was an exploded rear end. Bye bye Power Trax auto locker and bye bye rear diff. :(

3E5DD488-DCD9-466D-99C9-5962CA3D0066.jpeg


DCC00BC6-FF57-4F4A-AF58-40107B54F2C2.jpeg
BAF4DEA5-8845-4121-BE70-14F2425CF560.jpeg
2C5C2FF5-7750-4BC0-98B3-EAE0D6FDCF8C.jpeg
6E0328E8-B89A-42E8-B2D2-758860DDB165.jpeg


As luck would have it, a week later I found a matching set of Dana 44 Rubicon axles with HD steering, working air pumps, clean internals, and rear disk brakes! (My old Dana 44 had drums). Time to remove the Dana 30 up front and the exploded Dana 44 out back.

55D1B3BD-6D9A-4B63-9C25-251F524F41B7.jpeg


First order of business was scraping off all that caked on dirt, grease, and surface rust. I treated them with a few coats of rust preventative spray and painted them satin black.

891C471F-A4E7-491D-B36E-C2C52C22C59D.jpeg


There were a lot of “while I was in there” repairs I thought I’d tackle. Took care all the u-joints, ball joints, installed new front axle hub assemblies, bought new front disc rotors and pads, pressed on new bearings to the rear axle shafts. Basically a diff refresh, if you will, minus rebuilding the centers.

7213CFF3-74B6-4B98-8876-A80A4B2303E1.jpeg


84635D1E-780A-4749-A388-673C4203A70E.jpeg


Also took the liberty of installing new YJ brakes lines front and rear as the ones on there were too short.

Now was the time to upgrade components if I was ever going to do it. Out with the factory upper control arms, JKS lower control arms, JKS quick disconnects, JKS front track bar, spring lift and spacers, and dropped pitman arm.

I went with a full Currie / Rock Jock steering and suspension upgrade with full Savvy Offroad dual adjustable control arms with Johnny Joints. Antirock sway bar up front. I kept the rear factory sway bar and the existing Bilstein shocks.

The Savvy bits are very well built and look great!

6250DAFB-DF30-4247-8B6C-3E02F7A984C1.jpeg


Pic of rear diff installed with new diff cover.
CB87597A-CAF2-49C9-BD7D-63EEF22DD0F7.jpeg




Once I got it all put back together as best as I could, I relocated the air pumps to the engine bay under the brake booster, plumbed some new air lines and wired each pump to work on independent switches. I needed to buy a factory Rubicon switch bezel and cut out the dash trim pieces to fit. Finish looks as close to factory as I could make it.
7E099C41-4EB3-44FA-8856-8A637AFDBAF3.jpeg
EB5E4DD2-216D-4C9C-91F1-239F2DA15E70.jpeg


I drove the Jeep (slowly) to my local 4x4 shop and had them dial everything in on their alignment rack.

Got her back today and she drives better than ever. Still a bit bumpy (…bilsteins, new springs, worn tires…) and has plenty of flex. :)
D77464E9-6CF5-4547-ACB1-EA1E72A68EF7.jpeg


BEC1B1F8-F4F2-4D6E-905D-13FD56B42D8F.jpeg
8BD2A90A-3FBD-41AD-A3B9-0C3922241545.jpeg



A huge shout out to all the members on this forum but especially to @Chris @Jerry Bransford and @mrblaine for weighing in so heavily on the countless threads I poured through to take on this project and get it done right the first time.
 
Last edited:
Lots of skinny pedal
Perhaps. I gave it enough gas to try to overcome the obstacle without flooring it, but she just didn't want to climb.
Not running a real locker.
Agreed. There were a few times on the trail where one wheel on either front or rear diff didn't budge. The auto lockers the PO installed I assumed were getting tired and were most likely abused over time.
 
  • Like
Reactions: rasband
Perhaps. I gave it enough gas to try to overcome the obstacle without flooring it, but she just didn't want to climb.

Agreed. There were a few times on the trail where one wheel on either front or rear diff didn't budge. The auto lockers the PO installed I assumed were getting tired and were most likely abused over time.
Where on HC?
 
I needed to buy a factory Rubicon switch bezel and cut out the dash trim pieces to fit. Finish looks as close to factory as I could make it.

This is the first time I’ve seen this mod. Do you have additional details of the process or was there another thread on here you used as a reference?
 
Is this the time I rode with you? Looks likely since I believe you were on 33s and that was sketchy as hell.
It is. And I think we had just met in person that day or right before.

The 33s were right on the edge of being too small for several spots.
 
  • Like
Reactions: rasband
This is the first time I’ve seen this mod. Do you have additional details of the process or was there another thread on here you used as a reference?
I found it on thread in the forum. Parts easily found on eBay. That Rubi panel is pricey for a used piece of plastic. I’ll link the thread if I can find it again.
 
  • Like
Reactions: deadbeat son
Novak Conversions Jeep Wrangler TJ engine mounts