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some backstory....
viewtopic.php?f=33&t=24003


so project bearmonster is going to be modified from what it's original purpose was going to be, but will still have alot of the same goals that i originally envisioned.

right now, i want to prep the engine and possible find out some more info on a transmission swap possibility.

Since the engine is going to be overhauled for this project, i need to know three things.

Do i REALLY have to take the cylinder head off in order to replace the timing chain? (service manual said i had to, but dont know if it's a NECESSITY vs convenience.

also, while in the junkyard the other day, i cam across a 5 spd trooper (86 i think) is this a suitable 5 spd trans to use and still keep my 4wd? what will i need to make this work (IE what year trooper trans?) and would i use the trooper's clutch or the luv's clutch?

one more note. since last fill up, i calculated my gas mileage, and im down to only getting 17 mpg. there isn't anything that i'm doing different from a few months ago when i was getting closer to 24mpg. (With the 4wd off) I do plan to find an electronic dizzy and install that, but i'm having trouble finding the right one. (i did find one, but the shaft doesn't rotate well and i don't know if i can just take the guts out and transfer into my distributor.


i know it's alot of questions, but i cant seem to really find the answer i need.

thanks in advance guys!

-johnathan

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To the Oquirr hills for awesome thrills! Go-go 4wd, Activate!

-Removing the head for timing chain replacement: You have two little bolts (the ones that are easy to drop into the oil pan) that go through the head into the timing chain cover. Those would definitely have to come out. Is there a channel in the bottom of the timing cover that a seal goes in?, if so then the cover would have to be raised slightly to remove it unless the crank was out. Maybe that is why it would be better to remove the head. Don't really know, but since you are overhauling the engine anyway won't the head come off for that?
-The '86 & '87 5sp trannies are the best swap, cable operated & they are stronger than earlier models. They are also longer than your 4sp, so I would fab a removeable crossmember, it will make removal & installation lots easier. Driveshafts will also need the length changed.
-The Trooper clutch is the same as your 4wd LUV (8-1/2").
-No idea on the change in fuel mileage, my LUV has always gotten 17mpg, but it has big tires, lots of wind resistance. Part of it could be the fuel formula changing between warm & cold weather, or you are buying from somewhere that has more ethanol that previously.

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'78 Chevy LUV,1.9,4sp,headers,31's,SAS Dana 30,Dana 20,SOA rear w/Aussie Locker, rough body, bought new 12/4/78.
'87 Trooper,2.3,5sp,headers,31's,ball joint flip & spacer,Aussie Locker rear,Superwinch hubs,brush guard w/5.5K winch,more to come.

Yes if you carefully remove the little bolts from the head to the front cover you MAY be able to get the from cover off, I haven't tried it. However the head gasket extends over the front cover and a good chance it will get damaged and you will have sealing problems when you are done. Pulling the head is not that hard, I have replaced many head gaskets on Luvs. You can pull the head with the intake, carb, and exhaust manifolds in place. Just drop the exhaust pipe connection, unhook any hoses, fuel lines, wire connections, a vacuum line or two etc, remove the little bolt behind the head that holds the EGR crossover pipe to the block and lift the whole assembly off. Easier with two people of course.
But if the head needs planeing you will then have to remove the manifolds.

You don't have to remove the head, but if you do when you go back with the head use new head bolts and a quality head gasket(Felpro) i've been there done that. Alot of these cheap kits offered these days are ok but those gravite head gaskets just don't seem to hold up well.

well, the gasket is not in bad shape, but the book says it needs to come off. i just didnt want to do it if i didnt have to.

the first phase of project bearmonster is the overhaul of the engine. Clutch, timing chain /timing sprockets, electric fan, distributor upgrade, cleaning, and underhood wiring and peripheral accessories cleanup.

i just figured since the engine is going to be out, it might be a good time to get it all done in one shot.

as far as the transmissions go, i did find that 86 trooper with a 5 spd. im hoping to drop the rpms on the highway.

will i have to change the front shaft length at all? when i pull it, what other parts will i need to get it done?

thanks again guys! keep it coming!

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To the Oquirr hills for awesome thrills! Go-go 4wd, Activate!

as far as the distributor goes, would i be able to just pull the guts from a trooper and install into mine?

i found an electronic dizzy at a local auto dismantler, but the shaft doesnt rotate smoothly, and you can tell it may not be up to snuff. for 50 bucks, i dont want to take that gamble of getting a bad one. BUT if i can take it's internals out, and maybe just maybe get it to work under my cap, then i won't have to take it all out you know?

what do you guys think?

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To the Oquirr hills for awesome thrills! Go-go 4wd, Activate!