2004 42RLE to manual swap crank position sensor question

[dyermullet]

Hello,

I started the swap and ran into problem. 2004 TJ 4.0 42RLE converting it to AX15 using TJ bellhousing 2004 flywheel and 2004 manual trans crank position sensor.

The 2004 24RLE has the crank position sensor on passenger side above the starter in about the 2 o clock position.
My TJ bellhousing has the crank position sensor in the normal 11 o clock position (top on driver side).
I had researched all of this I thought this was only a 05+ problem, since the 2004 nv3500 used the 11 o clock position, I was surprised to find my sensor on passenger side.

I am trying to use TJ bellhousing (crank position sensor in the 11 o clock position), 2004 flywheel and 2004 manual trans crank position sensor. Is the engine going to run with my 2004 computer in this configuration?

I am hoping that their is a difference in timing of the windows on the flexplate and flywheel for the different crank position sensor locations. I am going to continue with the teardown will compare the flexplate with new flywheel. I will come back tonight and see if anyone has experience with this. Now that this happened I plan to get flywheel & bellhousing on and get the engine to fire before going any further.

 

[macleanflood]

Perhaps this will answer some questions?

Thread 'NSG370 to AX15 swap'

Apr 15, 2022

starting this thread to document my swap instead of doing it after the fact when my memory is fuzzy.

Background: my NSG370 pops out of reverse. In street use it's tolerable but it's exacerbated when backing against any resistance, such as uphill (like the 8% grade on my driveway) or if a tire has to climb a rock or a log on the trail. This is annoying at best, and at worst could be dangerous or life threatening if on a narrow mountain switchback in Colorado. I had an AX15 in my '99 TJ Sahara, I liked it better, and the cost of swapping is almost the same as a rebuilt NSG370. (this thread...

• freedom_in_4low
• ax15 nsg370 swap transmission
• Replies: 45
• Forum: TJ General Discussion

• 

-Mac

 

[dyermullet]

Thanks for the response.

Mine is a 04 not a 05-06. Is an 04 going to run with a 04 flywheel and CPS in 11 position? I lined up the flywheel and flex plate and they do have a difference in timing, it did not appear to be enough. Right now I am waiting on the CPS bolts, didn't know i needed them, was planning to use mine.

 

[macleanflood]

@NovakConversions might have answers.

@mrblaine most certainly will.

-Mac

 

[mrblaine]

Hello,

I started the swap and ran into problem. 2004 TJ 4.0 42RLE converting it to AX15 using TJ bellhousing 2004 flywheel and 2004 manual trans crank position sensor.

The 2004 24RLE has the crank position sensor on passenger side above the starter in about the 2 o clock position.
My TJ bellhousing has the crank position sensor in the normal 11 o clock position (top on driver side).
I had researched all of this I thought this was only a 05+ problem, since the 2004 nv3500 used the 11 o clock position, I was surprised to find my sensor on passenger side.

Nope, all the 42RLE transmissions from 03-06 have the CPS over the starter.

I am trying to use TJ bellhousing (crank position sensor in the 11 o clock position), 2004 flywheel and 2004 manual trans crank position sensor. Is the engine going to run with my 2004 computer in this configuration?

Perfectly fine.

I am hoping that their is a difference in timing of the windows on the flexplate and flywheel for the different crank position sensor locations. I am going to continue with the teardown will compare the flexplate with new flywheel. I will come back tonight and see if anyone has experience with this. Now that this happened I plan to get flywheel & bellhousing on and get the engine to fire before going any further.

No, the flex plate and flywheel have the timing notches in the same place for 03-04. The location of the CPS is in the same spot relative to the notches, just 120 degrees over. 03-04 are 120 apart, 05-06 are 180.

 

[dyermullet]

No, the flex plate and flywheel have the timing notches in the same place for 03-04. The location of the CPS is in the same spot relative to the notches, just 120 degrees over. 03-04 are 120 apart, 05-06 are 180.

That's the key to this then, and would explain how an 04 runs with two different locations.

Thanks for the help.

I need cps bolts before I can get it to run, I will post again when up and running.

 

[dyermullet]

Finally got it together and it is running and driving.

I am using a Novak AX15 it is difficult to shift into 2, upshift, downshift, or even just stopped difficult to get into second gear. Have to muscle/slam it into 2. I have good clutch release, no grinding shifting to R. All other gears are fine.

Not impressed has anyone dealt with Novak on warranty for one of these units? I will have to find time to call them on Monday.

 

[Steel City 06]

Finally got it together and it is running and driving.

I am using a Novak AX15 it is difficult to shift into 2, upshift, downshift, or even just stopped difficult to get into second gear. Have to muscle/slam it into 2. I have good clutch release, no grinding shifting to R. All other gears are fine.

Not impressed has anyone dealt with Novak on warranty for one of these units? I will have to find time to call them on Monday.

What transmission oil did you put in? Going lighter weight might help slightly.

Is it difficult to shift even with the engine off? If so, pull the shifter and try shifting by just pushing the forks. If those are difficult, it may be related to the transmission. If not, it may be the shifter.

Also, try it with both inner and outer shift boots removed. Sometimes those can add a lot more resistance than you might expect, especially if the inner boot isn't aligned properly.

Stock shifter or aftermarket?

 

[dyermullet]

What transmission oil did you put in? Going lighter weight might help slightly.

Is it difficult to shift even with the engine off? If so, pull the shifter and try shifting by just pushing the forks. If those are difficult, it may be related to the transmission. If not, it may be the shifter.

Also, try it with both inner and outer shift boots removed. Sometimes those can add a lot more resistance than you might expect, especially if the inner boot isn't aligned properly.

Stock shifter or aftermarket?

Redline MT90 same oil I run in my other AX15.
Difficult into 2 at all time.
No shifter boots installed was first test drive. Shifter not hitting anything.
Stock shifter that came with the novak trans with a TJ handle. Looks like a stock AX15 shifter to me.

I have rebuilt an AX15 have driven lots of miles with them, I don't have to fight with 2nd gear. I will put some more miles on it this weekend, but I don't expect it to "fix itself"

 

[astjp2]

Finally got it together and it is running and driving.

I am using a Novak AX15 it is difficult to shift into 2, upshift, downshift, or even just stopped difficult to get into second gear. Have to muscle/slam it into 2. I have good clutch release, no grinding shifting to R. All other gears are fine.

Not impressed has anyone dealt with Novak on warranty for one of these units? I will have to find time to call them on Monday.

I am on my 3rd nsg overhaul, in 2 miles

 

[tnjeepguy]

Dustin Anderson
Novak Conversions
https://www.novak-adapt.com/index.htm
Technical Sales Advisor & Marketing Manager
dustin@novak-adapt.com

on our Forum

 

[Steel City 06]

Redline MT90 same oil I run in my other AX15.
Difficult into 2 at all time.
No shifter boots installed was first test drive. Shifter not hitting anything.
Stock shifter that came with the novak trans with a TJ handle. Looks like a stock AX15 shifter to me.

I have rebuilt an AX15 have driven lots of miles with them, I don't have to fight with 2nd gear. I will put some more miles on it this weekend, but I don't expect it to "fix itself"

Huh, that's frustrating.

If you still have the other car with an AX-15, you could try swapping the two shifters to see if that does anything. (It's a total shot in the dark though.)

 

[dyermullet]

Update:
Did that initial drive approx 10 miles. Difficulty shift into 2 as I said above. Let it cool off about 5 hours, drove it real quick 1 mile seemed to shift better. Drove it yesterday approx 60 miles in city shifts into 2 no problem. Don't know what the problem with initial drive was, 2nd gear synchro had no grip on 2nd gear and it "fixed itself". Happy with it now.

 

[astjp2]

Maybe a little breakin

 

[machoheadgames]

Update:
Did that initial drive approx 10 miles. Difficulty shift into 2 as I said above. Let it cool off about 5 hours, drove it real quick 1 mile seemed to shift better. Drove it yesterday approx 60 miles in city shifts into 2 no problem. Don't know what the problem with initial drive was, 2nd gear synchro had no grip on 2nd gear and it "fixed itself". Happy with it now.

I dug through your posts after conversing about the SYE. Just for anyone reading in the future, this behavior is 100% normal. I got an AX15 from Novak around 9-10 years ago and it did the exact same thing, the shifts just felt wrong and blocky. After about 30 miles or so it had cleaned up its act and felt perfect. It must have something to do with break-in or clearances loosening up or something. No idea but it’s a night and day change as the trans starts to shift correctly.

 

[dyermullet]

Its not a break in or loosening up. The syncro ring had no traction on the cone face of the gear. It must have came with some heavy assembly lube between the ring and cone. After that melted/washed away worked well.

 

[hear]

No, the flex plate and flywheel have the timing notches in the same place for 03-04. The location of the CPS is in the same spot relative to the notches, just 120 degrees over. 03-04 are 120 apart, 05-06 are 180.

I should definitely know this, but are the windows on the flexplate/flywheel all identical? Or is one different to indicate where TDC is? It only bolts on one way, so it's timed to the crankshaft, but one of the would have to be different for the crank sensor to be able to tell the PCM where TDC is.

If all the timing windows were identical then it wouldn't matter where the sensor was located.

 

[mrblaine]

I should definitely know this, but are the windows on the flexplate/flywheel all identical? Or is one different to indicate where TDC is? It only bolts on one way, so it's timed to the crankshaft, but one of the would have to be different for the crank sensor to be able to tell the PCM where TDC is.

If all the timing windows were identical then it wouldn't matter where the sensor was located.

They are split up into 3 groups 120 degrees apart on the early ones.

 

[dyermullet]

I should definitely know this, but are the windows on the flexplate/flywheel all identical? Or is one different to indicate where TDC is? It only bolts on one way, so it's timed to the crankshaft, but one of the would have to be different for the crank sensor to be able to tell the PCM where TDC is.

If all the timing windows were identical then it wouldn't matter where the sensor was located.

The cam sensor would indicate where the engine is on compression vs exhaust stroke.

They were identical like Mr Blaine confirmed for me. Moving the crank sensor to the 11 o clock position worked out perfectly.