Well over the weekend I came to own both a 96 2wd XJ and an 83 OM617TD for just under $650. The wife and I got the wild notion(in the matter of about 2 hours) that this would be a great swap. So now I've got some of the parts, and I've been doing a ton of more than casual reading on this swap. I've decided to go with the Koch adapter to retain the stock 2wd AX15. I'm also going to try to use as many of the stock Jeep odds and ends as I can, like the 4.0L rad and gauge sending units. So here are some of the things I've found as "points of interest".

1) The stock Benz alt won't do for me. I'm first going to try to swap the Jeep 90am Denso unit and if that fails maybe I'll try for a GM or something. Any input on a 90-100amp alt that fits easily?

2) Steering to pan clearance. From what I have read everyone is in agreement that a 3" lift is needed to clear the sump. But from looking at pics of completed trucks it doesn't look like you're getting the added height of a 3" lift kit on an XJ. So I'm wondering are people putting lift springs in to compensate for the added weight of the diesel and netting minimal/no lift? Based on what I could find for a weight of the OM617, a pair of Grand Chero front springs would be better suited to hold up the weight and retain a "stock" looking ride height. Is this a fair assessment, or am I missing something. I don't mind if I lose the nose down rake for a more level stance, but I don't really want to have a lifted truck in the end. But if it has to be then it will be.

3) The Koch website says to align-mark or index the Benz crank and flywheel/flexplate so as to not loose the balance relationship after removal for reassembly. But the adapter kit doesn't use the stock flywheel/flexplate so why bother?

OK sorry about all that and I'm sure I'll have more questions, but that's it for now. Thanks

 

Hi! Welcome to this site! I think you will find it more user friendly. I used a GM alt and it was almost a bolt-in deal, as for the springs, mine had the weaker coils, so it sat lower to begin with. I raised it a total of 3in in front. Yes the motor is alot heavier than that 4.0, I used stiffer springs.

 

My understanding is that some small percentage of the OM617's have a flywheel that is balanced with the crank as opposed to being neutrally balanced as is the norm on American vehicles. The idea behind marking the location of the MB flywheel on the MB crank is that you would take the MB flywheel to the machinist and have them check to determine its balancing. If it is neutrally balanced then your good to go with the Jeep flywheel. If not, then the Jeep flywheel has to be balanced to match the MB flywheel balancing.

I can't recall reading about anyone who has had to rebalance the Jeep flywheel yet and I think most folks are playing the odds and skipping this step. My thought is that if the MB flywheel is truely part of the engine balancing, then why did MB not design the flywheel so it could only be bolted on one way?

 

That would mean that an automotive engineer would have to think first. From what I've been able to tell over the years, thinking isn't the first thing they do.

 

I am running a Chevrolet flywheel and I have no vibration,
Vette




This shows a auto flywheel but have a straight gear flywheel from a 80 model truck in it now auto did not work out well

 

Well I'm glad to know that the chances of getting the motor out of balance are pretty well ziltch.

I got my adapter ordered last night and it was shipped today. I'm hoping to see it by the end of the week, with it shipping from PA to VA.

 

Good luck on your build I have got to omit that building was more fun than driving it.
Not to say that driving it not ok but building is the most fun.
Vette

 

You're right, building it is always the most fun.

 

Yep, it's a sickness!

 

I had the mb and jeep flywheels equalized and there was a 4 gram adjustment to the jeep flywheel needed. I don't know if it would have been noticable had I skipped that step. I'm also using the crank and bell adapter from Koch enterprises, currently bolted up to motor and looking nice. start lifting the jeep tomorow, then dry fit again. I am finding fte's build pics to be very useful. especially oil cooler and motor mounts.
btw--fte, ill be thru portland/vancouver friday afternoon/ early eveish..... if your avail id take u up on seeing your rig.