I've a '95 Tracker with a 2.7 conversion and 4 speed auto w/ lock up; it's my daily driver.  Bought it last spring from the owner who did the conversion although I was considering doing one into the later gen two doors.  Had 19,000 miles on it when I bought it; has just over 50,000 on it now; I drive 165 miles a day, 4 days a week.  Although I didn't do the conversion so there are many things I don't know which are XL7 and which are Tracker if you guys have questions you can ask and I can try to figure it out if I can get the time.  I have all the XL7 shop and electrical manuals and a '95 manual.  If you live anywhere near central WI and want to stop by and check it out and go for a ride you're more than welcome.  Only difficulty I've had is I had to remove the driver's side engine mount and bend it for clearance so I could remove and replace the oil filter.  There's a 2 in body lift so access to the filter is easiest through the wheel well with a strap wrench on a 12" extension.  Just another little thing to think about.  I believe he used the stock 4.30 speedo gear; with the Tracker 5.13 gears and 255/70/15 tires it's right on the money.

The other problem is poor fuel mileage....

I've a '95 Tracker with a 2.7 conversion and 4 speed auto w/ lock up; it's my daily driver.  Bought it last spring from the owner who did the conversion although I was considering doing one into the later gen two doors.  Had 19,000 miles on it when I bought it; has just over 50,000 on it now; I drive 165 miles a day, 4 days a week.  Although I didn't do the conversion so there are many things I don't know which are XL7 and which are Tracker if you guys have questions you can ask and I can try to figure it out if I can get the time.  I have all the XL7 shop and electrical manuals and a '95 manual.  If you live anywhere near central WI and want to stop by and check it out and go for a ride you're more than welcome.  Only difficulty I've had is I had to remove the driver's side engine mount and bend it for clearance so I could remove and replace the oil filter.  There's a 2 in body lift so access to the filter is easiest through the wheel well with a strap wrench on a 12" extension.  Just another little thing to think about.  I believe he used the stock 4.30 speedo gear; with the Tracker 5.13 gears and 255/70/15 tires it's right on the money.

The other problem is poor fuel mileage....

So are you running the speedo cable up to speedo and wire off to the ecm (vss input)?  And what year is your 2.7 shop manual?  Are you using 95 dash?
Sounds like Muskegtracker is getting close to the road.  I am still a ways out (been working on race car for ZUKIWORLD CHALLENGE).

I've a '95 Tracker with a 2.7 conversion and 4 speed auto w/ lock up; it's my daily driver.  Bought it last spring from the owner who did the conversion although I was considering doing one into the later gen two doors.  Had 19,000 miles on it when I bought it; has just over 50,000 on it now; I drive 165 miles a day, 4 days a week.  Although I didn't do the conversion so there are many things I don't know which are XL7 and which are Tracker if you guys have questions you can ask and I can try to figure it out if I can get the time.  I have all the XL7 shop and electrical manuals and a '95 manual.  If you live anywhere near central WI and want to stop by and check it out and go for a ride you're more than welcome.  Only difficulty I've had is I had to remove the driver's side engine mount and bend it for clearance so I could remove and replace the oil filter.  There's a 2 in body lift so access to the filter is easiest through the wheel well with a strap wrench on a 12" extension.  Just another little thing to think about.  I believe he used the stock 4.30 speedo gear; with the Tracker 5.13 gears and 255/70/15 tires it's right on the money.

The other problem is poor fuel mileage....

Thanks for the info but I'm pretty much done.  How do you like it?  I mean power wise?  and what kind of Fuel economy are you getting?

Well, it's been a while since I've posted anything really new...so here you go!

XL Tracker V6

Whadaya think?  

I have replayed the video a couple times.  Looks and SOUNDS great. 
Is the motor swap done, or are there still loose ends?
How is the shifting?  Did you have to use a BCM?
What did you end up doing to solve the Air Pump problem?

I have replayed the video a couple times.  Looks and SOUNDS great. 
Is the motor swap done, or are there still loose ends?
How is the shifting?  Did you have to use a BCM?
What did you end up doing to solve the Air Pump problem?

Thanks!

I guess I still have a couple of items to take care of.  Wiring lights, finishing the dash and installing it.  Hoping for this weekend to have it together well enough to run on the highway.  It shifts great, has lots of grunt in the low end (and top end ).  I did use the BCM.  It cured many problems I had with lights flashing in the combo meter.  Since mine doesn't have an air pump but a small electric motor (it's called motorized control in FSM) I have it plugged in right now.  Funny thing it only works if you stop the motor from spinning (the computer then expects the front end to be engaged).  So I am driving right now with vise grips  .  But I have a heavy duty resistor on order, that I hope with mimic the draw on the system enough to trick the computer into engaging 4x4.  Make sense?

As for speed, I got it up to 80 MPH (130 KPH) down the gravel road by my house.  It will easily break the tires loose at any speed on gravel.  It is quite peppy and more often than not I am in need of traction, not power - as expected.

I kept the 5:12 gears even though the XL-7 has 4:25.  With my slightly taller tires (235/75R15) I think it all evens out - maybe a little slower actual speed per 1000 RPM.  At 80 MPH it's rev's are around 3000 RPM.  We'll see how it does on the highway with fuel mileage before I think of going with 4:60? out of an auto Trakick.  I did check it between a known distance (2 km) and found it was pretty dang close!  All that said,  I love how low geared it is in low + 4low .

Hey muskegtracker, very nice work!  Sounds very mean.

With the logic I have seen in the wiring diagrams, it does make sense.  After the race, I will start on my Tracker again, and probably come to you for solutions.
Glad to see yours up and running.

so... what would you charge to do another... hehehe...

man im going to feel inadequate at the zuki meet. mines just as it was last year. its going to be tight if i can get it lifted by the meet, money has just been tight...

that thing sounds mean... you guys bringing both again this year?

so... what would you charge to do another... hehehe...

man im going to feel inadequate at the zuki meet. mines just as it was last year. its going to be tight if i can get it lifted by the meet, money has just been tight...

that thing sounds mean... you guys bringing both again this year?

If you're serious PM me...   I'm up for doing any work on any rig...

If you're looking for a coil and strut spacer lift...I can probably hook you up, if you're interested.

I don't think I can convince my bro to bring his out this year (even though it is coming along nicely!).  He might just come out with me.  I guess we'll see!

So my idea worked!  I used a 1 ohm 50 watt resistor to trick the computer into thinking the front axle engaged. hehehe...

Here's the motor I replaced


and here's the resistor

It gets pretty warm after a couple of shifts in and out of 4WD.  It's made to handle some heat with it's aluminum body and cooling fins.  We'll see how long it lasts.

The math says that I need at least 150 watts, but that is for continuous power and this resistor only gets a few seconds.  When I explained to the guy at the supply shop that I needed a resistor to run 12VDC with 12amps he said," what are you doing?  Trying to make a heater?"  The resistor would probably burn your hands if you cycled it too many times.  But rarely, if ever, will I be shifting in and out of 4WD that often.

Here's another project I've completed.  Since I will be using push-button 4WD, I won't need the TC shifter hole so I used my laser to cut out a rubber gasket and polycarbonate cover for the hole.



A little dusty...(gravel roads...nuf said)




And here's a pic of the engine bay.  (p.s. - I've even added cruise control!)

Nice work with the resistor!  Crafty!

So my idea worked!  I used a 1 ohm 50 watt resistor to trick the computer into thinking the front axle engaged. hehehe...



and here's the resistor

It gets pretty warm after a couple of shifts in and out of 4WD.  It's made to handle some heat with it's aluminum body and cooling fins.  We'll see how long it lasts.

The math says that I need at least 150 watts, but that is for continuous power and this resistor only gets a few seconds.  When I explained to the guy at the supply shop that I needed a resistor to run 12VDC with 12amps he said," what are you doing?  Trying to make a heater?"  The resistor would probably burn your hands if you cycled it too many times.  But rarely, if ever, will I be shifting in and out of 4WD that often.

So then the comuter only runs this when you make the shift into and out of 4X?  Going to have to check my wiring diagram!!  The 2003 uses an air pump, bet the 05 (my new motor) has same setup as yours.
How is it running now?

Get to start back on mine next week.

Quote from: muskegtracker on April 21, 2010, 09:25:32 AM

So my idea worked!  I used a 1 ohm 50 watt resistor to trick the computer into thinking the front axle engaged. hehehe...



and here's the resistor

It gets pretty warm after a couple of shifts in and out of 4WD.  It's made to handle some heat with it's aluminum body and cooling fins.  We'll see how long it lasts.

The math says that I need at least 150 watts, but that is for continuous power and this resistor only gets a few seconds.  When I explained to the guy at the supply shop that I needed a resistor to run 12VDC with 12amps he said," what are you doing?  Trying to make a heater?"  The resistor would probably burn your hands if you cycled it too many times.  But rarely, if ever, will I be shifting in and out of 4WD that often.

So then the comuter only runs this when you make the shift into and out of 4X?  Going to have to check my wiring diagram!!  The 2003 uses an air pump, bet the 05 (my new motor) has same setup as yours.
How is it running now?

Get to start back on mine next week.

The computer does a check at every startup and runs it at every T-case gear change.  It's running great! I think I will add a couple of wires (yah, more...I know...) so that my dash lights dim properly, then its fully ready for re-assembly and welding a couple of rust holes in the floor.  The tracker drives like it's 10 years newer.  I can't get enough.  I smile every time it starts up.

I had a bit of a race with my Dad (he was on his quad - Polaris 550).  He didn't have a chance. 

My only concern now is the gearing.  The XL-7 comes with 4.25 gears and 235/60R16 and the Tracker is running 5:13 with 235/75R15.  I'm tempted to go with the higher gears from an auto (I can get some for free), but would rather go with bigger tires($$$).  It seems to be out by a little over 10% (Tested the odometer with another vehicle between two points).

Nice work with the resistor!  Crafty!

Thanks