90 4.2 to 95xj 4.0 Swap Build Thread - Page 7

yjcrawlr · 05-08-2009, 06:52 PM

I really don't have much money at all because my 4.0 and new gasket kit were free. If I count all the parts I sold off my 4.2 I am under $500. I have spent in the $700-800 dollar range including machine work, clutch kit, timing chain, water pump, oil pump, gauges and misc. parts. I have recovered near $400 from part sold off the 4.2. And Swampwalker you will need the xj computer.

Swampwalker3 · 05-08-2009, 09:11 PM

So, harness, vacuum lines and all the other little doo dads are out of the yj. tomorrow morning I am pulling the engine out of the YJ, give the tranny and case to the guy that bought them, and proceed with the undoing of all that's under the XJ.

I think Im going to have to use the ugly shifter/box thing for my shifter until I can afford a lokar or something neat.

May also go ahead and do the cj dash look since my dash is 3/4 of the way off anyway. Kinda tricky figuring how to remove the glovebox..

Curiously, the bulkhead, I can just plug and play into my YJ plugin, right? Or will I have to take it park that's bolted to the fire wall off as well and replace the one on my fire wall?

Yeah, I have the computer and all of that. Was just curious.

yjcrawlr · 05-08-2009, 09:43 PM

I unplugged mine at the firewall and plugged the xj one in. If I had it to do over again a complete yj harness to run my engine and have the cab side would have been nice. You can plug the xj harness into the firewall of your 89, and it will only take two more wires to make it run. Gauges and all the other stuff is why I had a complete yj harness. I dealt with pulling the glove box when I put in my tuffy a while back, a few of those nuts that hold on the handle are fun. Let me know if you have more wiring questions.
Selby

Swampwalker3 · 05-08-2009, 11:41 PM

Sweet, thanks.
The two more wires are the two that you described earlier, correct?

If I didn't get an entire XJ, I'd of gotten a 91 yj harness, but I bought an entire xj so it should be a little smoother than trying to peice things together. I hope to have it running by Sunday night.

yjcrawlr · 05-09-2009, 08:57 PM

Sorry for the slow reply Swampwalker, I have been working on my cage today. The two wires are the ignition hot and the hot start, the same ones I was talking about earlier. So are you plugging the xj harness to your 89 harness at the firewall?

yjcrawlr · 05-09-2009, 09:31 PM

Today I worked on the cage add ons to finish up some welding before I put in all of the gauges and stainless dash. here is what I have so far. I hooked Willy up with the same additions, he did give me a 4.0 and all.

one of my welds

Willys jeep

Swampwalker3 · 05-09-2009, 11:01 PM

Show us the Dash.

Yeah, I ripped out the YJ motor today. TOmorrow I will be addressing the XJ motor. If I understand everything, I want to plug the Xj harness into the plugin on the driver side of the firewall. Use the light harness from my YJ and just replug it to the same area. Hook the XJ computer somewhere under the hood for easy access.

Looking to use two e-fans from the XJs. 1 for all time and the 2nd for hot times. Like how they run factory. Will turn the AC into OBA. Hopefully, removing the 4.0 is just as easy as the YJ was.

By the way, are you just SOA or do you have a lift?

yjcrawlr · 05-10-2009, 08:26 AM

Yeah the dash, I decided to finish the cage completely before installing the dash. I didn't want to splatter my new gauges and stainless with slag from the cage welding. The stainless is all cut and I made a template for the bends in the brake. So right now if you guys want to see what a yj looks like with the dash ripped out that is what I got. I am SOA on 1.5 RE's in the front and XJ springs in the rear. I ended up wiring my headlights on a stand alone system. All the headlight, parking, and turn signal switches were all ripped out by the previous owner.

As you can see the dash is pretty sad right now. The gauges are ripped out, the tuffy glove box is out, The dash is getting the rust conversion treatment today and the stainless will go in soon. I will post the pics when I get there.

Swampwalker3 · 05-12-2009, 01:16 PM

Just realized you were in the pic welding..

Anyway,
From what I gathered I had to splice the 5 wires but still used the XJ bulkhead (Turns out I can't). Shame to find this out, Finally got the bulkhead off. I don't fully understand the bulkhead concept. Do I match up the wires(use) from the YJ bulkhead and mate it onto the harness where the xj bulkhead was?

The 5 wires thing is just telling me that's what I need to get done for it to run, but still need the other wires for whatever lights, gauges and stuff like that?

Not huge on wiring but my buddies who are are yet to be found when I'm working on the jeep.

yjcrawlr · 05-12-2009, 05:43 PM

When I refer to the bulkhead connector I am talking about the connnector that mates to the fuse box on the inside of your jeep. I pulled my fuse box(old 90 original) loose and moved two of the connectors to correspond with the engine side(cherokee 4.0) of the connector. This is all it took to make my jeep run. When you plugged the 95xj harness to the 90 fuse box two moved pins and fire! Not everything else worked but mechanically everything was up and running. Everything on the cherokee engine bay harness has one way connectors so it is pretty hard to mess up.

Swampwalker3 · 05-12-2009, 10:49 PM

That's what I refer to when I say Bulkhead. I wonder if it'll work for me. Just getting mixed information searching through threads and getting feedback from other people who have done it.

I'll check to see if my bulk head matches yours from your earlier description on pin moving and if it's the same I'll try your method first since it's less wiring, then the "5 to fire thing" if I fail. The rest of the harness I have labeled so I should be ok with that. Just have to fish out the TCU harness and the motor is free of electrial and then time for the easy part.

Did you ever get your electrical up and going? I still haven't gotten a good diagram yet and for some reason lack grabbing FSMs..

Thanks again

yjcrawlr · 05-13-2009, 01:26 PM

Everything was working except tach, water temp, and oil pressure. I pulled all the gauges for the dash and gauge swap. But it still all works and is drivable. I will be running new wires for the gauges anyway. I think you can just connect the bulkhead connector, pull the fuse panel loose and move those wires and you will be good to go.

Miller_TimeII · 05-13-2009, 08:13 PM

I am in the same boat as swampwalker, the easy part is mechanical, I have heard that there are about 12 opr 15 wires extra on the XJ harness, I have no clue which ones they are, if anyone could shed some lights that would be great.

yjcrawlr · 05-14-2009, 06:44 AM

I didn't pull all the wires from the engine side of the harness, you can get it running with all those still in there. Then pull them out later when you know for sure they are not needed. I don't plan on pulling any wires from the engine side of the harness only ones on the cab side that I am not using.

yjcrawlr · 05-21-2009, 05:46 PM

The cage build continues, I am adding a few more tubes, some paint, and moving on to the dash. Everything still works on rocker switches even though its pretty ugly right now. I am thinking two front to back tubes in line with the v-bars. What do you guys think? Had a expensive build day, I set the back of my xrc seat on fire and broke the windshield.