Go BottomJohn deere gator 4x6 turbo project
 | antichip
Join Date: Oct 2010 Posts: 8 florida 
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2010-10-08 174442
First things first. My name is josh and I am in central florida, somewhere north of tampa.
I bought a JD gator 4x6 about 2 weeks ago for 400 dollars.
It was rusted in half where the pedals are. When I first saw it it looked like it had been hit by a mac truck, with the steering wheel kissing the seat. Then the guy started it. I almost messed myself, guy said it hadn't been started in months. anyway a week later we agree to the 400 and I go pick it up with no seats and no lift for the bed(man that bed is heavy).
So really the only thing holding the front end on at this point was a half inch strip of rust and the control cables.
2 days of tweaking and tacking and the front was straight and secure. Air ride shocks from gold wing replaced front stock shocks.
I bought a turbo off a guy on craigslist, fabbed up an exhaust and intake. Made up the oil lines and bam.
So we put wheels on and put it down, and the brakes are locked up, so the next day we proceeded to tear down the tranny. There were some rust and chunks, everything cleaned up real nice.
Started driving and no boost.
I don't know if any of you gator guys have tried messing with the fuel pump at all, but I could find no info on it.
So by going from the JD 330 engine manual I deduced my fuel adjustment screws were behind the freeze plugs. high idle on the top and main fuel in the front. After getting the plugs off I saw the specialty tool screws. After some searching the internet for a few I decide just to make them.
Couple hours on the milling machine and I have a perfect set of adjustment tools for the Gator tne66c diesel.
I am now making 5 psi until I get to the cvt limit. at cruise I am at 0 boost, no vac.
I don't really need alot of help with this, But I am looking for a a different size cvt. My issue is that it does 18 mph. I do a fair bit of driving in it, couple miles a day maybe. I can give it as much power as I want but it will still only do 18. I would like to do 35 or 40.
My other thought is to find or retrofit or something to give me a 2spd tranny?
Anyway, as it sits it is freaking awesome, and sounds even better.
Well there it is.
Main goal for this is to be a show off at shows and mudfest type events.
later.
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 | kthompson
Join Date: Oct 2005 Posts: 5275 South Carolina 
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2010-10-08 174452
But what you have done has not increased the top rpm so the speed would still be the same, correct? You sure seem to have good mechanical ability but with the brakes on our gas gator sure would not want any faster speed (it also runs about 18 mpg or near it). Then the expert on Gators is Gatoraider and he will pick this up no doubt. ....
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| antichip
Join Date: Oct 2010 Posts: 8 florida
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2010-10-08 174455
I do not need the brakes very often at all, but they feel very good now that I got them re surfaced. ....
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 | earthwrks
Join Date: Dec 2003 Posts: 3853 Home Office in Flat Rock, Michigan
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2010-10-08 174458
Something to consider about shocks is one size does not fit all---they are designed specifically for a particular purpose. You may have lucked out if they work for you. As far as speed goes an easy way is simply taller tires, but if you don't have the torque or power to get you rolling it will take longer. Not to mention taxing the brakes since it will take longer and more effort to stop. ....
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| jspec12
Join Date: Aug 2010 Posts: 33 Commerce Township MI
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2010-10-08 174461
Cool project! Take some pictures! I am not sure why but my 6x4 goes 25mph. It looks like i have the stock clutch too. There is a post somewhere about using a different clutch which replaces the 18mph unit. Any chance you can take some pictures on how you fixed the front end? I have similar rust issues. ....
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| antichip
Join Date: Oct 2010 Posts: 8 florida
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2010-10-08 174463
It is a fun project. I would kill for 25. 18 is from my gps, and it is consistent. The former owners caretaker said the engine and drive system are less than 500 hours old, I am not sure of the age, I just found the serial number today. I can take a couple pics of the repairs. jist consisted of removing alot of rotten pan, and placing a channel piece in the interior box sides, and rails on the bottom running from just behind the seats up to the front steering box. I actually have alot of welding to do. I need to take a 2x2 tube from the very back to the front seats then follow the angle of frame to the front past the steering shock area up to the push bumper area.
As far as having the torque to run bigger tires I am rushing to get the hitch set up so I can pull something just to get to use the torque I have for more than like 1 or 2 sec.
Larger tires are on the drawing board, but the turbo came up for the right price. ....
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| jspec12
Join Date: Aug 2010 Posts: 33 Commerce Township MI
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2010-10-08 174464
24.95 if you want to be exact. That is gps speed! Mine is a gas motor if that matters. It looks to be bone stock so I am either lucky or just stupid :) ....
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| gatoraider
Join Date: Nov 2008 Posts: 544 Maryland 
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2010-10-09 174465
Sounds like you're having a good time. You are right, when the clutches are maxed out you are done. Don't know if your frame is strong enough, but the easiest way to get more speed, other than larger tires, is removing the center tires and using that axle to gear up the rear axle. Find yourself some larger sprockets for that axle, lengthen your chains and you're in business. You could probably weld the new sprocket to the old one as long as it is big enough for the chain to clear the old one, or you could cut the teeth down to clear. You could cut the hub down to line it up with the back. I think the transaxle will handle it. they are tough inside. You will actually be turning it slower inside. ....
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| hardwood
Join Date: Dec 2002 Posts: 3583 iowa
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2010-10-09 174476
The Gators have came a long way since our first on a 4 X 2 with the turf type tires. Pitiful slow and even a hint of mud you were stuck. Then an HPX 4 X 4 that about wore the starter out form the %^&*^&% thing dying every time you put it in gear. Now our XUV 4 X 4 is all I need, plenty fast and never fails to start and never dies when you shift it thanks to fuel injection.
The current speed/horsepower race between the Gator/Polairs/and whom ever else reminds me of the muscle car days of the 50's and 60's, what one did the other outdid six months later.
I haven't driven the latest high speed Gator YET, guess I just don't want to be tempted.
Frank. ....
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| jspec12
Join Date: Aug 2010 Posts: 33 Commerce Township MI
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2010-10-09 174477
My buddy has a suv 620i it does about 30 maybe 35. Just a little faster then mine. Suspension is pretty nice to. What you really need is the new canam commander 1000cc it is electronically limited to 110mph. $14500 I just wish I had he spare change to pick one up. ....
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| hardwood
Join Date: Dec 2002 Posts: 3583 iowa
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2010-10-09 174478
Mine is the 620i engine in the XUV. I've never timed it for sure but the dealer said about low to mid thirtys.
The new three cyl diesel is supposed to go mid 40's, that's just too fast for me for farm chores and to have grandkids running it around.
I can't believe it will be as trouble free as the old 4 X 2 that didn't have any CV joints four wheel drive componets, and all that, but so far no problems.
Frank. ....
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| antichip
Join Date: Oct 2010 Posts: 8 florida
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2010-10-10 174498
I had used the shocks on a previous project and knew what to expect. They are air so I can go up to get it more stiff. I may or will when I find them, switch to remote reservoir adjustable air or oil. Air is cool couse I could have shock purge valve dump into exhaust by an igniter, and use propane(since it will be there)to fill shocks upon start. Just an extra valve.
I really like the look of the old 4x6.
I would not buy a new JD gator
I could not buy a new JD gator or anything driving
This was one of those things for 400 dollars.
friends say im lucky, I say I'm just a little more prepared.
If I need suspension, well before I started my crap it was way smother than say a friends ez-go lifted on same really bad road.
Brakes
I will do a full speed stop test later, my next step in brakes has always been to add a disk on the rear spindles. Air assisted finger brakes on the wheels, split the brake pedal, and all the e brake crap. Anyway brakes not issue and easier to source than the CVT parts. As all I need are disks and spindle hubs.
If I spend 1/4 the cost of a new one on this. Well wow. I doubt I will have that much to work with unless I get a deal to show it off( I'm trying). The man hours involved in all of it will be kink of crazy though.
So does anyone know the primary clutch input shaft size?
How about the secondary?
My main concern it power transmission to the ground. Does not look like alot to break in the tranny. LOL
OK enough I could go on all day, Id rather go do something. ....
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| antichip
Join Date: Oct 2010 Posts: 8 florida
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2010-10-13 174553
I'll try and get a few pics up here if I can. taken from my phone.2 I am using my phone as a wifi hotspot. So we got a pic of the paint scheme for the front pusher. It will get tore down and redone during the final build-up, but nice to see something other than black and brow. ....
Link: public gator albulm
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| antichip
Join Date: Oct 2010 Posts: 8 florida
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2010-10-14 174579
Well that was the turbo and the air cleaner.
The cover to my stock filter unit got ran over yesterday. I really wanted to use it, so I must source another top. I have a small cone pre-filter on the side port of the filter can and the main in is taped off.
I live on super dusty lime-rock roads. After a week my vacuum gauge was in the red showing check filter.
I turned up my fuel again and now I am not boosting nearly as much, but it feels like it has as much power. I will be turning the fuel back down this afternoon.
I think my oil blow by is almost resolved.
I will get back into looking for a new cvt next week. Play with the propane injection this weekend I hope.
....
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| antichip
Join Date: Oct 2010 Posts: 8 florida
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2010-10-19 174650
This is another pic of the front end repairs. The real improvement here is the 2 support struts shown in the pic.
My boost issue was just a leaky exhaust manifold. hitting 6 psi now.
I am not familiar with the 620i engine. 35 of 40 would be a perfect top speed. It would not get used much, but there are times.
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| jspec12
Join Date: Aug 2010 Posts: 33 Commerce Township MI
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2010-10-19 174656
I see the repair on the floor! I have the same exact problem except mine is not as bad. I can feel the steering / dash section flex when I am driving. The person who attempted the repairs on mine welded plate all along the bottom of the center section. To me it looks like a crappy design on John Deers part. The frame goes from about 3 feet wide to a foot wide at the front section. They should have made it much beefier expecially knowing that people would salt and plow snow. Here are some pics of my 6x4 :)
http://smg.photobucket.com/albums/v491/jasonspector/gator
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Link: Pics of my 6x4
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