NV4500 And Atlas Transfer Case Swap
The team at Petersen's 4-Wheel & Off-Road insist on having the control of a manual transmission while rock-crawling and hillclimbing, so they ditched the automatic that came with the Cummins and found a nv4500 five-speed. With some help from Richard Daley of fordcummins.com the AEv team was able to find the right adapter to fit the automatic-ready engine to the manual transmission. next, the team installed a new Centerforce flywheel and high-performance dualfriction clutch. Since the engine had been moved back, the transmission crossmember was also moved back 1 foot and notched so that the Advance Adapters two-speed Atlas transfer case could be clocked down to avoid contact with the Jeep floor pan.
Axles And Driveshafts
Driveshafts from JE Reel were used because they are just 2 inches in diameter, which helps the Jeep clear rocks, but are made from strong 0.120 steel, which can take the abuse of the 5.9L diesel. The skinny shafts send the Cummins output to 91/4-inch (front) and 101/2-inch (rear) AAM Power Wagon axles fitted with selectable electronic lockers and 4.56 gears at the front and rear of the Jeep.
Superlift Kit And "Torque Fork"
In order to properly support the weight of the diesel engine, the stock Dodge Ram coils and shocks were used up front, along with adjustable Rockrunner link arms from Superlift. The rear lift blocks were removed, along with the overload leaf spring, which was replaced by a Superlift add-a-leaf spring. To prevent axle wrap, Superlift built a custom torque fork that's based on the one used in the black Diamond x-2 suspension kit. A Superlift skidplate was also used to protect the transfer case from trail damage. Since the diesel-heavy Jeep would be riding on big 42-inch tires, the team at PSC Motorsports installed a hydraulic ram-assist system that will prolong the life of the steering box and make the JK easier to steer.
42-Inch BFG Tires On 20-Inch Bead Locks
With all the frame-swapping and body modifications, (including some fender trimming), it was possible to mount the Jeep on 42-inch bF Goodrich Mud Terrain KM2 tires and keep it riding about the same height as a stock Jeep on 37-inch tires. The bFGs were installed on 20x10-inch Poison Spyder Customs SpyderLock wheels that are cast from sturdy A356-T6 aluminum. The wheels are specifically designed as beadlocks, (not cut and welded), with 6061 T-6 aluminum rings, and have a large center bore that fits easily over the Warn wheel hubs and Dynatrac Free-Spin kit.