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Thread: 2.5-4.0 swap

  1. #1
    That Guy RnEmOvr's Avatar
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    Default 2.5-4.0 swap

    OK so few weeks ago I blew my 2nd 4cyl, i decided i was done w/4 bangers so i shopped around and found a 6cyl/5spd trans/t-case/computer/harness for $900 i went and picked it up and started pulling the 4cyl, i don't have pics of me pulling the trans or case but here is some pics of me pulling the 4cyl, here is the link the my photo bucket account [/URL]since i told my ex GF to take lots of pics, she took over 100 just of me pulling the motor, although i didn't keep all of them,


    list of things needed is few post down, i will update it as i go

    also i know i am to skinny, but not even the Army was able to fatten me up, so deal with it

    1st i had to borrow a few factory spares so it would even fit on the trailer,



    nice easy unload, just lift trailer w/forklift



    the start



    even the now ex GF got dirty and helped out (thats my dad i cant thank him enough)



    rest is just random stuff we removed, i wont lable it all





    yes my dad is sitting up under the jeep





    all undone

    Last edited by RnEmOvr; 04-10-2009 at 20:10.
    Just another lifted, locked and cut up TJ, Have Cummins, will tow

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  2. #2
    That Guy RnEmOvr's Avatar
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    like my engine hoist?








    all empty





    I'm going to beat gas prices Flintstones style!!






    thats all till this weekend, i go pick up my new frame side motor mounts tomorrow mopar part #52058864 (left), and 52058865 (right).


    Special thanks to Brown Dog for the part numbers, and the new HD engine side mounts that i need to take pics of, and to Tomb Raider who has given me lots of info as well


    and yes parts from the 4cyl are for sale except the alternator
    Just another lifted, locked and cut up TJ, Have Cummins, will tow

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  3. #3
    That Guy RnEmOvr's Avatar
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    new motor mounts came in thanks brown dog, also picked up my factory frame mounts



    Just another lifted, locked and cut up TJ, Have Cummins, will tow

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  4. #4
    That Guy RnEmOvr's Avatar
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    here is list of things needed to do the swap,

    *motor (duh) try to say with your year group (the year of your jeep), 97-99 and 00+ although my swap is from a YJ
    *trans, the AX-5 will not bolt to the 4.0 plus it will not hold the
    power either ( i dunno about autos)
    *t/c the 4cyl has less splines then the 6cyl so it wont work either
    *computer, must be year/motor/trans/model specific
    *harness (for most its plug and play, for some reason mine was not) XJ harness will not work, this is where year specific comes in play the most
    *Upper left motor mount 52058865 (dealer part)
    *Upper right motor mount 52058864 (dealer part)
    *Reinforcement left motor mount 52058845 (i am making these though)
    (dealer part)
    *Reinforcement right motor mount 52058846 (i am making these though)
    (dealer part)
    *Exhaust need re done from header to cat (the cat is same and so is rest of exhaust)
    *Drive shafts (front is now longer, rear is now shorter, doing a belly up is good idea at this time)
    *Fuel lines from frame to fuel rail, you may be able to make the 4cyl ones
    work, but mine didn't have enough play in them, $50~ from dealer part # is
    52100272AH
    *wiring diagram (you may or may not need it but still nice) http://www.ahdol.com/
    *Vacuum lines the goto intake manifold, dealer only parts, 53030615 (valve
    cover to intake tube), 4854265 (valve cover to intake manifold) and 4854163
    (evap canister lines) all rang in at <$30 from dealer so no to bad, although yours may be different this is what worked for me
    *Power steering lines, the 4cyl ones are longer, they will work but you risk them getting into the belt/fan, KOI has the pressure line at $15 but they do not have the return (they show it as bulk hose, the bulk hose works from the reservoir to pump but you need line with fitting from box to reservoir) advanced has the return for $25~ both were next day items
    *Radiator hoses (upper and lower)
    *Intake tube, the filter box fits but the tube is different, I found someone who did a CAI and bought theirs. Or you may do a CAI. I chose not to for i play in mud and the filter clog up to easy when open like a CAI filter is.
    *Fan shroud, you may trim the one from the 4cyl


    these are different from the YJ motor, and the TJ harness, if using TJ motor you will be fine
    *sensor in thermostat housing, (the one from 4cyl will work)
    *O2 sensor in intake, (the one from 4cyl will work)
    *O2 sensor in exhaust manifold, (the one from 4cyl isn't long enough)
    *throttle body (TJ has extra sensors)
    *crank position sensor (the one from 4cyl will work)



    things i bought since i had it all out anyway
    *Brown dog mml and HD motor mounts
    *SYE/CV shaft
    *Belly up skid
    *New belt
    *Complete tune up from ignition coil to the plugs



    The following parts will interchange from your 2.5 to the 4.0;
    *Power steering pump
    *Alternator
    *Fan
    *Radiator (some say the cooling isn't the same, some say its fine, i know it fits and hooks up with new hoses)
    *I do not know about A/C but i believe it will
    *Evap canister, although none of the lines will

    If you have any questions send me a PM
    Just another lifted, locked and cut up TJ, Have Cummins, will tow

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  5. #5
    That Guy RnEmOvr's Avatar
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    finally stole the ex GFs phone and uploaded the pics here you go, sorry they quality isn't that good its from a camera phone

    cut old mounts off, gotta love plasma cutters!!




    all gone



    well remember my engine hoist? well it wouldn't work due to bumper sticking out so far, so instead of taking bumper off, we pulled out dads F550 work truck with hoist




    getting motor in place



    checking for clearance



    we then marked mounts, pulled motor, tacked mounts and tested motor again, mounts were to far back,



    so moved them up little bit and tried again

    Just another lifted, locked and cut up TJ, Have Cummins, will tow

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  6. #6
    That Guy RnEmOvr's Avatar
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    they fit so dad fully burnt them in





    his welds are getting better, i dont think these are going anywhere, but just to be on safe side be are making braces this week,






    that is all for now, once we make the supports i will bring the jeep home and things will fly then, also if anyone has a truck and would be kind enough to tow my jeep home that would help alot, i will give you money plus gas, i have trailer
    Just another lifted, locked and cut up TJ, Have Cummins, will tow

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  7. #7
    That Guy RnEmOvr's Avatar
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    finished the mount supports, the ex GF even helped again

    all cut out,


    cleaning them up some




    welding them in,





    all done, motor going in tomorrow


    Just another lifted, locked and cut up TJ, Have Cummins, will tow

    Random Jeep Stuff

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  8. #8
    That Guy RnEmOvr's Avatar
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    well i got the motor and trans bolted in today, but got so excited i forgot to get pics, i will get them tomorrow, but here is pics of us redoing the steering bracket



    Just another lifted, locked and cut up TJ, Have Cummins, will tow

    Random Jeep Stuff

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  9. #9
    That Guy RnEmOvr's Avatar
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    motor is in!!! will start wiring tomorrow





    new brown dog MML and engine side mounts



    and trans

    Just another lifted, locked and cut up TJ, Have Cummins, will tow

    Random Jeep Stuff

    My YouTube page

  10. #10
    That Guy RnEmOvr's Avatar
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    few pics, will get more




    well finished up the harness, started with what you see sitting on the tire in above pics, then to this



    then finished up with this, (from first plug back was cut off)

    Just another lifted, locked and cut up TJ, Have Cummins, will tow

    Random Jeep Stuff

    My YouTube page

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