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Unread 11-11-2013, 02:02 AM   #1
kingolaf1987
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95 jeep yj engine swap thoughts

i have an 95 yj with a 2.5l manual tranny. the compression went to crap a few weeks ago. i bought a 92 Cherokee with a 4.0l ho in it for 200 bones. (it runs but rusted out) ive heard it dumb to put a 4.0l in a 2.5l spot. my thoughts, if i do it the 4.0l will get 2000 dollars dumped into it. ( im emotionally attached to this jeep) or do i rebuild the 2.5l? its got 31 mickey Thompson on it. and a 2.5 inch suspension lift on it. or do i save the head ache and sell it and buy a wrangler tj with a 4.0l in it and start over with a lift kit and interior......on and on. the cherokee is all complete...and i have time to rebuild in the garage. please help me choose an idea.

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Unread 11-11-2013, 07:15 PM   #2
uberxj92
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The 4.0 is an easy good swap. It gets 1 MPG less than the 2.5 and is almost twice the motor. The bell housings are the same, motor mounts are close and all you have to do is use the xj wire harness and ecm. Your 2.5 should have 4.10 gears. That 4.0 will smoke the tires.
And you can stroke the 4.0 cheap and pretty easy too.
Other options are full v8 swaps where you get into fabbing and drive train issues. And fuel economy especially off road.
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Unread 11-12-2013, 02:43 PM   #3
jeepn4life92
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I 2nd the 4.0 swap, especially if the cherokee is a manual also, that 4.0 is gonna be a great engine for you and it coupled with the 4.10's would be a great combo for 33's
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Unread 11-17-2013, 02:30 PM   #4
kingolaf1987
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sounds like a rebuild. we be working on taring it out this weekend. will i be chasing my driveline because of the big engine? (break downs)? and the 92 cherokkee looks like the same rear axle as my yj. take it for parts or?????
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Unread 11-17-2013, 10:30 PM   #5
uberxj92
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You're drive line should be fine as ling as you drive smart.
If both rears are Dana 35's then everything in the xj rear except for the ring and pinion should be the same.
Everyone has opinions on axles there's tons of other threads for that.
The axles you have should hold up to 33's as long as you don't hammer the go pedal a lot.
You can pull the carrier out if the xj axle. Junk the rest. I wouldn't worry about keeping any of the parts. If you break yours then that's the excuse you need to upgrade.
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Unread 11-19-2013, 05:40 PM   #6
kingolaf1987
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ill post pics after the tare out and during the rebuild.
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Unread 11-20-2013, 03:55 AM   #7
uberxj92
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Cool
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Unread 11-24-2013, 11:18 AM   #8
94jeepman
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I did the 4.0 swap it was easy but it will be easier for you with a manual transmission hardest thing for me was adding 2 more fuel injector plugs. Other than that you need to lengthen your fuel lines and do new motor mounts.
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Unread 11-24-2013, 11:20 AM   #9
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As far as axles go I had 33 inch tires with 4.11 gears and I wasn't necessarily nice to the jeep but the axles are still in one piece
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Unread 08-17-2014, 10:24 AM   #10
yj95dawg
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Not sure if you're still working on this, but I bought a 95 YJ where a 2.5->SBC was started. I wish I had just put a 4.0 in it.

Rebuilt t/c, tranny swap, new driveshafts, adapters, engine mounts, lots of $ later, I'm almost done.
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Unread 09-16-2014, 05:30 AM   #11
drod086
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Hi guys, I'm new here. I'm currently building up a 99 wrangler 4.0 to swap into my 95 with a 2.5. I was just wondering what the purpose of moving the motor mounts was ie. Is it a drive line issue, body/motor interference issue fan/radiator issue. I plan on using the 32rh tranny and keeping my Terra low t-case with sye. The cross member has a built in 1" drop. I just need a little clarification on what is going to bump into what if the mounts aren't moved. Thanks.
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Unread 09-16-2014, 08:28 AM   #12
StanF
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The back of the engine will be In the firewall. The mounts have to be moved.
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Unread 09-16-2014, 02:28 PM   #13
drod086
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I measured the 4.0 today and the location of the engine mounts currently on the frame set up for the 2.5. From inside of the bracket on the motor to the bell housing on the 4.0 is 6" longer than on the 2.5. And the 4.0 is 2" longer on the front side. So I see an electric radiator fan in my "to get" list. Is 6" forward on the frame mounts accurate? Also when I move them I will be raising the motor a few inches. And I'm fairly certain I no drop motor mounts are going to compensate. Any suggestions on weld in or bolt on mounts that would work best for keeping the engine as close to stock in frame height. I like where my center of gravity is currently. LoL.
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Unread 09-17-2014, 07:31 AM   #14
fishadventure
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One of these days I need to grab a square and tape measure and create a baseline for this as I have two 4.0 frames and two 2.5 frames at my disposal. I think that a properly installed 4.0 /can/ use a mechanical fan if that is your mindset but electric offers some benefits. Even CJs had belt-driven fans...
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Unread 09-17-2014, 09:13 AM   #15
StanF
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Quote:
Originally Posted by drod086 View Post
I measured the 4.0 today and the location of the engine mounts currently on the frame set up for the 2.5. From inside of the bracket on the motor to the bell housing on the 4.0 is 6" longer than on the 2.5. And the 4.0 is 2" longer on the front side. So I see an electric radiator fan in my "to get" list. Is 6" forward on the frame mounts accurate? Also when I move them I will be raising the motor a few inches. And I'm fairly certain I no drop motor mounts are going to compensate. Any suggestions on weld in or bolt on mounts that would work best for keeping the engine as close to stock in frame height. I like where my center of gravity is currently. LoL.
You should really start your own thread...

Bolt up everything and drop it in the Jeep. Use the rear transmission mount to locate everything. Tack weld the mounts in place. Remove the engine. Finish welding the mounts.

I'd recommend that you do a bunch of research on your swap. There are a bunch of great threads on it here in the forum.
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