PT Cruiser V-6 Conversion!

[2002Gold]

Originally Posted by PTrockcruiser

Nice project. You've given me hope on mine seeing how little firewall chopping was needed.
Couple questions. I read this post over sort of quick so I may have missed it. Do you have the rear axle in there yet? Did I read that you're going to use a rear axle from a 2002 Wrangler and convert to leaf springs? The dana 35 or 44?

No, I have not installed the rear end housing yet. And yes, the rear end housing that I will be using is from a 2002 Jeep TJ Wrangler like the one shown in the picture below. The one that I will be using is a Dana 35 with 3.07 ratio. This will match up with the 200R4 GM transmission that I'm using. The rear end housing came with coil over springs, however, after taking a very serious look under the car, it is very clear to me, that if I use leaf springs, it will require less structual members and work. If I had known I was going with a leaf spring suspension, I would have done some research on the Jeep's that use the leaf spring suspension. I'm thinking of making the rear suspension a bolt system. I will try to do most if not all of the welding on a work bench. What year is your PT? What engine are you thinking of using? Aloha, Tommy.

[PTrockcruiser]

It would be a lot easier (and stronger) to use a 8.25 axle from a Cherokee if going to leaf spring. I'm surprised you went with 3.07 gears. Then again I'm used to the off road world where we're going to 4.10, 4.56, etc.
Why not stick with coils?
About how much hight and width do you think you cut out on your floor/firewall?
What are you going to use for a radiator?
My PT is a 2001. I'm thinking I want to get a crashed Liberty for the motor, tranny, T-case, rear axle, floor sheetmetal, and wiring harness. It sounds logical in my head anyway. I do have a Ranger with a 4.0 I could use, but for some reason I think I might be better off staying with the Dodge family so that maybe wiring would match up better.

[rte662006]

I think ladder bars and coil overs are the way to go.Easy to install and plenty of adjustability.I think with leaf springs you will have a hard time getting the car to sit at the height you want.And who knows how ride quality will be with leaf springs.You will probably have to have custom leafs made and that might get expensive.

[2002Gold]

Originally Posted by PTrockcruiser

It would be a lot easier (and stronger) to use a 8.25 axle from a Cherokee if going to leaf spring. I'm surprised you went with 3.07 gears. Then again I'm used to the off road world where we're going to 4.10, 4.56, etc.
Why not stick with coils?
About how much hight and width do you think you cut out on your floor/firewall?
What are you going to use for a radiator?
My PT is a 2001. I'm thinking I want to get a crashed Liberty for the motor, tranny, T-case, rear axle, floor sheetmetal, and wiring harness. It sounds logical in my head anyway. I do have a Ranger with a 4.0 I could use, but for some reason I think I might be better off staying with the Dodge family so that maybe wiring would match up better.

Here is the cut mark I made. This outline was for the 1st Chevy V-6 application. I made a cardboard template from a Chevy 3.8 V-6 bell housing pattern. I then placed it against the firewall and lightly followed the outline. I then expanded the outline outward about 1 inch to allow for clearance. I intend to use the stock PT Cruiser AC/Heater box, so I placed the template right up to the bottom of the AC/Heater box. If you don't intend to use your AC/Heater box, you can remove it and make your cut higher if you like. In the bottom picture you can see that the top of the transmission is very close to the bottom of the AC/Heater box. It is about 1 inch away. If you use a V-6 engine or smaller, the cut that I made should be sufficient. If you use a V-8 engine, then the AC/Heater box has to go because the heads will end up the dash. I'm not into the off road stuff, so the Jeep Wrangler rear end should work out fine for me. If you intend to use your AC/Heater box be careful where you make you cut because the 3 studs you see on the firewall is what mounts the AC/Heater box to the firewall. You will have to stay away from those studs if you intend to use your stock AC/Heater box. I had a radiator built to my spec's. I had the radiator shop follow the stock PT Cruiser bolt patern, then install 3 cores. The stock PT Cruiser radiator only has 1 core. Then the inlet and outlet tubes where placed in the area's near the thermostat housing and the lower suction side of the engine. It would be in your best interest to use everthing from what ever donar car you use. And yes, if you stay with the Dodge Family, you will be better off, it will make things easier for you. If you take a real good look above your existing rear suspension, I think you will note that it will take allot of structual work to use a coil over suspension. You would probably have to cut into your floor to create the frame work necessary to support the coil over suspension. That's just my opinion. Don't forget that your stock gas tank has to go as well. Good luck, Tommy.

[2002Gold]

Originally Posted by rte662006

I think ladder bars and coil overs are the way to go.Easy to install and plenty of adjustability.I think with leaf springs you will have a hard time getting the car to sit at the height you want.And who knows how ride quality will be with leaf springs.You will probably have to have custom leafs made and that might get expensive.

I have been in contact with a suspension specialist, he will be fabricating two custom leaf springs for me to my spec's. He has everything figured out and is waiting for my final specifications. As I mentioned in my previous thread. To install a coil over suspension will create much needed structual supports, and welding under the car. This is what I'm trying to avoid. I don't have the luxury to get a coil over suspension installed. I'm disabled, and sometimes I have to do things differently to get the job done. It would certainly be wonderful, however, at this point, I just have to settle for second best. Thank you for your support and concerns. Aloha, Tommy.

[AlTheKiller]

Originally Posted by PTrockcruiser

It would be a lot easier (and stronger) to use a 8.25 axle from a Cherokee if going to leaf spring. I'm surprised you went with 3.07 gears. Then again I'm used to the off road world where we're going to 4.10, 4.56, etc.
Why not stick with coils?

you could also look into a D35 from a YJ which would be leaf sprung. you should be able to pick up a used D35 for ~20-50 bucks and if its not strong enough for you (which it should be) you can toss in some 27 spline chromoly axle shafts and a c-clip eliminator.

[2002Gold]

Originally Posted by AlTheKiller

you could also look into a D35 from a YJ which would be leaf sprung. you should be able to pick up a used D35 for ~20-50 bucks and if its not strong enough for you (which it should be) you can toss in some 27 spline chromoly axle shafts and a c-clip eliminator.

Very good info! I checked out the flickr.com and jeep forum.com website links you provided. I looked at all of the different builds. Very good pictures and nice jeeps. In the mid 60's, I had a Willy's Jeep which my brother in-law gave me. I installed a Chevy 283 cubic inch V-8 engine in it with a Chevy T-10 trans. I purchased my parts from a company called Rancho Jeep Supply. Not sure if they are still around or changed their name. It worked out well. I think I was 17 years old at the time. I kept it for a couple years and then sold it. I wish I kept it. For now, I will install the rear suspension that I have. If it does not turn out for what ever reason, I will then look into your suggestions listed above. Thanks again for your support and all this awesome info. Aloha, Tommy.

[quicksilverdon]

Originally Posted by 2002Gold

You're going thru all this work, and will have rear drums? Nothing around w/ rear disks? With "go", you need "whoa!".

[2002Gold]

I generally bring my parts in from the Mainland. Here in Hawaii, these types of parts are hard to find. If anyone see's a good deal for a disk brake, leaf spring rear end housing set-up, let me know. The length has to be the same as the rear end housing from a 2002 Jeep TJ Wrangler. I don't want to end up cutting wheel wells, axles and the housing itself. Thanks for your support and concerns. I appreciate it. Aloha, Tommy.

[Hooligan]

Originally Posted by 2002Gold

I generally bring my parts in from the Mainland. Here in Hawaii. Aloha, Tommy.

Now that we know where you are located, maybe the questions will change from the Mainland to Hawaii. If your profile had been filled out earlier we would have known.

BTW: that is a great project you are doing. It wouldn't be something I would try as I do not have the knowledge nor equipment to even attempt it.