Engine Swap Help for a Newbie - JeepForum.com
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post #1 of 16 Old 09-21-2012, 08:29 PM Thread Starter
PeterSyz
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Engine Swap Help for a Newbie

I'm running a 2.4L 4 banger in my 91 YJ and it's just not getting the job done, I need more power. I'm currently at the beginning of my search and I know that there are alot of different engine swaps that are possible. (4.0, 302, 5.2, etc.) I would like if you guys could give me some suggestions on the best (easiest, fastest, most cost effective) that you have done. Most likely going to do it myself. Any help is appreciated, Thanks guys!


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1992 4.0L YJ | Pennsylvania
1998 5.9L ZJ | Kansas

Last edited by PeterSyz; 09-21-2012 at 10:19 PM.
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post #2 of 16 Old 09-21-2012, 10:16 PM
lutzke21
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Dude, not trying to dissuade you, but even if you had the engine, tranny and transfer case, $1,000 to $2,000 is still a little unrealistic.

Fuel system needs to be worked out, depending on what engine you pick (TBI vs. FI vs. carb)
Cooling system, stock is only good for the stock engine.
Wiring system-cheapest is doing it yourself, no small task. You want the engine to think it's still in it's original home.
Motor mounts, trans mount

Not to mention the barely-capable-stock Dana 35 rear end.

Engine swaps have a way of nickle and diming you.

-Scott

'94 YJ on 35s

Sept '14 YJOTM
July '13 YJOTM

M C L M M
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post #3 of 16 Old 09-21-2012, 10:22 PM Thread Starter
PeterSyz
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Okay, forget the money. I just want to get some ideas considering I'm in the beginning of my process. I'm not looking to do this in the next week, more like a year or two from now.

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1992 4.0L YJ | Pennsylvania
1998 5.9L ZJ | Kansas
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post #4 of 16 Old 09-21-2012, 10:38 PM
lutzke21
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Cool, research the hell outta Novak and AA's website. That's a good first place to go. Tons of other stuff on here and other forums too. Search is your friend.

I have a TBI 5.7, 4L60E out of my old suburban for my swap. But now I'm considering a new 5.3 instead. I've been planning mine for about 5 years now, but just don't have the liquidable funds right now. Either way I chose Chevy because the engine is so popular (huge aftermarket), the market has a ton of solutions for this swap, and.. well I have the drivetrain (assuming I go with my 5.7).

In the meantime, I've slowly upgrade other stuff in preparation (axle, suspension, etc.).

First thing is selecting your powerplant, because most everything else will be specific to that decision.

-Scott

'94 YJ on 35s

Sept '14 YJOTM
July '13 YJOTM

M C L M M
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post #5 of 16 Old 09-24-2012, 09:38 AM
bmgadg
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Late model magnum mopar is probably the most straight forward swap out there. No changes to fuel pump, cooling system, gauges, etc. Wiring is pretty much the hardest part. Dana 35 rear is something that should be addressed though with any v8 swap.
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post #6 of 16 Old 09-24-2012, 05:24 PM
lutzke21
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You're running a 4-cyl rad with your Magnum?

-Scott

'94 YJ on 35s

Sept '14 YJOTM
July '13 YJOTM

M C L M M
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post #7 of 16 Old 09-25-2012, 01:51 AM
mrmark
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The 4.0 fits nicely, just have to move motor mounts and get matching wiring harnesses. It is the easiest and cheapest of all swaps as the Jeep came with them. Best way is find a full vehicle (XJ) and use the entire driveline as the transfer case won't match up from a 2.5 to a 4.0 due to different outputs shafts sizes on your tranny.

I am just finishing this up. I had a donor YJ and life was easy (except the wrong wiring harness) probably could have done it in a weekend if everything was clean and ready to go. I did lot's of cleaning and repainting while I had it apart.

Wave as you pass me :D

The problems of owning 2 Jeeps ... I never know which one to work on or which YJ gets the next mod ...
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post #8 of 16 Old 09-25-2012, 11:57 AM
bmgadg
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Quote:
Originally Posted by lutzke21 View Post
You're running a 4-cyl rad with your Magnum?
This one http://www.oconeeoffroad.com/servlet...rangler/Detail but it's physically the same size as my original, just the outlets relocated.
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post #9 of 16 Old 09-25-2012, 01:45 PM
Why J?
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Easiest most cost effective is to sell your Jeep and buy one with the 4.0. Beside doing that I am in the middle of a 5.3 swap and it is close to 4k.
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post #10 of 16 Old 09-25-2012, 03:32 PM
OKwranglerYJ
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It's hard for me to agree with these guys. I'm in the process of gathering parts for the 2.5 to 4.0 swap and after I'm done I will be $1500 dollars into it. If I had been patient, I could have waited and parted the parts xj out and made most of my money back but I chose a different route. As far as selling mine and buy one with a 4.0, absolutely not an option my jeep is MY jeep and I'm taking it to the grave.
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post #11 of 16 Old 09-25-2012, 04:06 PM
ltrail
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I would have to disagree also. I checked before buying on my 2.5-4.0 swap and after replacement of engine, trans, and tcase I was looking at $1000+/-. I bought an 89 Chevy 1500. I got my engine trans, tcase wiring, fuel pump etc. I paid 400 for truck with bad head gasket. I ran up about 600 at machine shop, 250 for rebuild kit, and 150 for tranny kit and tq conv. A bit of steel since its for the xj and some hoses, and etc. Fully possible on a budget if you have the time and patience. Takes about 5 wires to run the engine and kept all my original wiring to splice in lighting and such. In a yj just build or buy some mounts and a cross member and call it done.

Not far off at the 2k mark. I did have to spend a lot on steel, but he has a solid platform and I put it in a darn tuna can.
Doable, just shop around for a donor. Wrecked, broken, or otherwise . I'm all about budget beaters! And jeeps with SBC



Forgot to mention after selling parts and scrapping the cab/bed I made more than my initial investment back. Say it with me....free Chevy drivetrain.

84 xj 350tbi, sm465, 203/205, 60/70. links and other junk.
what size sawzall blades does it take to fit 40's?
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post #12 of 16 Old 09-25-2012, 08:43 PM
mrmark
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I bought a rusted POS YJ with a 4.0 AX15 for $700 and now have a total of about $1200 into the project and have already sold $400 worth of parts and still have an AX5 and NP 231 along with a whole bunch of small parts to sell. By the time I am done I should just about break even and come out of it with a 4.0 AX15 setup.. well worth it for me.

Wave as you pass me :D

The problems of owning 2 Jeeps ... I never know which one to work on or which YJ gets the next mod ...
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post #13 of 16 Old 09-26-2012, 09:16 AM
oteps
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I broke even or made money on my 4.0 swap. Didnt really keep track. Sold the 2.5 $200 ax5 $100 Bought xj for $400 parted what I could and took the rest to the scrap yard. But I also put a new frame under it and soa at the same time, that cost a little $$.
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post #14 of 16 Old 09-26-2012, 10:23 AM
youngjeeper11
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Chevy 5.3, easiest, best bang/horsepower for your buck, most options, most aftermarket support, most info, easiest wiring, most reliable engine.

After doing a TBI 5.7 swap, 2 5.3 swaps, and a 4BT swap, 5.3 is the best/easiest/cheapest.

Give Novak a call and ask them the same question, they will tell you what I just said.

I have never done a 4.0 swap, but I always said if you are going to go through the trouble of an engine swap, you may as well just go all the way.

Jeep 1:Used to have a 93 YJ 2.5l- 3.5" Black Diamond, Chevy TBI 5.7l V8, SM 465 4 speed, 8.8 rear( 4.10, L/S), rhinoline, Mile Marker 9000, NP 231, Had to sell it due to college
Jeep 2: 89/91 YJ, 4BT Cummins, NV4500, NP 231, Old Man Emu 2.5" suspension lift, 1" body lift.....Runs and drives, but very much a project
Interned at Novak Conversions 2 summers ago

Ask me about my 4BT Cummins Motor Mounts!!
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post #15 of 16 Old 09-26-2012, 04:14 PM
mrmark
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Quote:
Originally Posted by youngjeeper11
Chevy 5.3, easiest, best bang/horsepower for your buck, most options, most aftermarket support, most info, easiest wiring, most reliable engine.

After doing a TBI 5.7 swap, 2 5.3 swaps, and a 4BT swap, 5.3 is the best/easiest/cheapest.

Give Novak a call and ask them the same question, they will tell you what I just said.

I have never done a 4.0 swap, but I always said if you are going to go through the trouble of an engine swap, you may as well just go all the way.
How much does the 350 swap cost by the time you go from start to finish?

My 4.0 swap cost a total of $1200 which I am slowly recouping back as I sell spare parts so it should cost almost next to nothing. So far i am back down to $800 and have lots more crap to get rid of.

So how can anything be cheaper unless they are paying you to do it.

Wave as you pass me :D

The problems of owning 2 Jeeps ... I never know which one to work on or which YJ gets the next mod ...
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