My unbuild to rebuild

Burnerman · 03-10-2010, 09:20 PM

Well I'm gonna make one new post on my unbuilding of a 92 YJ and installing the 4.0 HO engine, AX15, np231 and wiring into my 89 YJ 4.2L automatic. I will probably swap in ALL of the 92 wiring harness into my 89 so it's easy to troubleshoot down the road. My only issues will be wiring in my hardtop connector into the harness. I love threads with pics so I'm posting them in this thread.
I picked up a running 92 with a rotten frame. The engine runs good and the hard doors and top are in great shape. They're going on my son's 93. So did the seats. I have been tearing down the tub and stripped that down to just sheet metal. Sold that today so that's gone. Here are some pics of my progress.

Burnerman · 03-10-2010, 09:25 PM

Got to tearing it apart.

green89yj · 03-10-2010, 09:28 PM

So you are pulling the 4.2 and putting in the 4.0? I'm in the middle of the same swap and can't wait to have someone else to talk wiring with. That is the most daunting part of the whole swap.

Burnerman · 03-10-2010, 09:30 PM

Found some rusty areas......

Burnerman · 03-10-2010, 09:39 PM

Quote:

Originally Posted by green89yj

So you are pulling the 4.2 and putting in the 4.0? I'm in the middle of the same swap and can't wait to have someone else to talk wiring with. That is the most daunting part of the whole swap.

That's what I think/thought. Since I have the complete harness and the donor Jeep I'm using the whole harness but after pulling things out you really don't have to. You can hook up the proper wires from the engine harness to the current engine harness in the 4.2 engine bay. You can use the VSS from a 91 YJ and keep your mechanical speedo. The tach is the only thing I'm not sure of. Anyway I gutted the tub of its wires and everything else for that matter//

Burnerman · 03-10-2010, 09:44 PM

I sold the tub today and we lifted it off and put it in his pickup. Now I could get to the goodies underneath!

Burnerman · 03-10-2010, 09:52 PM

I'm going to do an external slave on the AX15. I just need the front input seal retainer. If anyone has one let me know. I'll need a complete new exhaust I found a crack in the exhaust manifold. Gotta tidy up the engine. I have all of the heating stuff if anyone needs pieces but the cables are spoken for.. I saved every bolt from the body so if someone needs or wants a factory bolt for something let me know. I have to get some cash and get all the stuff before I start tearing into my 89.

JeepsOLot · 03-10-2010, 10:11 PM

Now THAT is what I call cancer!!!!! Hope you guys didn't drive that home,

Good luck with the swap!!!

Jerry

Burnerman · 03-11-2010, 08:42 PM

No driving home like that. Actually the frame held up only because of the rear body mounts. I did drive it onto the trailer. It had no brakes, every brake line was rotted out. I did get on it in 1st and 2nd in 4wd lo in the parking lot before I loaded it up and nothing broke loose. Oh as a note when I put it in 4wd to get it to move because of a frozen rear brake it went right in. The vacuum disconnect system worked fine. I did sweep up about 50 lbs of rust off the garage floor twice already and there's probably another 50 lbs on the floor! I'll be pulling the engine out next week when I get my work truck home. It's nice to have a F450 with a 2 ton 20' crane on it for a work truck! I'll get the engine on the stand an do some cleaning,replace the water pump and thermostat. I need a new exhaust manifold or header ( if I have any $). I have my external bellhousing coming and I'll need to get that all squared away also. I wanna get the engine and trans all ready to slap in then go for the swap. I figure 2 days to get my nose off engine, trans, t case and wiring out of my 89. Then 2 more days to get all the "new" in. I'm hoping my stock cat back exhaust will work with the 4.0 for awhile. It's 2" and the 4.0 is 2 1/4". Once I sell my 4.2 and TF999 I'll get a nice cat back exhaust.

Burnerman · 03-12-2010, 06:01 PM

Well I got the bell housing today and cleaned it up. Drained and flushed out the AX-15. Then sat down and spent more $$. Ordered a new manifold from 1A Auto. I got my 4.2 manifold from them and they had the 4.0 manifold with lifetime warranty for $130,free shipping. They're great for cheap decent parts. Then I ordered the input bearing retainer and seal for the external slave swap, $140 for both from 4wdtruck. Then I ordered the door parts for my son's full doors from Quadratec. Stopping at Advance Auto to get the cap rotor and spark plugs and order the front pipe.

K4KAS · 03-12-2010, 06:50 PM

Moving right along! Man what great progress!
It looked to be in great shape, other than the frame of course. I guess I forgot how bad the salt belt is. Thats one of the worst YJ frames Ive ever seen! Keep posting pictures, Ill be watching you as you progress!

Burnerman · 03-15-2010, 08:59 PM

Today I pulled the clutch off. It's like new...

I have a new one coming so I"m gonna install it anyway.the flywheel still has the resurfacing marks on it.

I didn't wanna chance it and I'll feel good know it's new. Anyone need a Pressure plate and disc for a 4,0 ax-15? cheap!
I pulled the thermostat housing and thermostat. The cooling passages look like the day it left the factory.

The housing is pretty sketchy looking so I have one of them coming along with a new water pump. There was alot of oxidation at the hose connections and after removal I found out the water pump bearing is bad. I have the external bellhousing cleaned up and ready to go. The long snout seal retainer and new seal are on their way. I pulled the manifolds and cleaned up that side of the block. I cleaned out the intake runners on the intake. UPS and FedEx are dropping off a bunch of stuff tomorrow.

I should have everything ready with the engine and trans by the weekend.
I need to sit down with the harness and trace out and remove the hardtop/rear wiper stuff from the 92 harness while it's out. I need to graft that into my son's 93. He's going to use that top and I need to get the wiring from my 89 HT/rear defroster and graft that into the 92 harness. That's going to be my biggest hurdle. I don't mind wiring but I don't think the Haynes or Chilton manuals have that in the schematic...Anyone have the FSM and can send me a schematic??

JeepsOLot · 03-15-2010, 09:37 PM

I have a '92 FSM, both volumes, just have to find a way to scan it as mine is busted.

Jerry

Burnerman · 03-15-2010, 09:45 PM

That would be a big help. maybe even a pic. I see the rear wiper switch in the Haynes but I have also found that the Haynes wiring info isn't very good. I can't locate the Chilton manual, my son had it last. The Chilton manual is a little better. I really don't wanna have to undo the whole harness...

Burnerman · 03-16-2010, 07:58 PM

Got the new clutch and water pump today. Installed the new clutch after getting my @@@ kicked by the pilot bearing. The new exhaust manifold came so I got that on along with the water pump. I took a look at the harness and I think I'm gonna cut the hardtop pigtail off after I install the harness and I figure out what does what. I read a post on here claiming all YJ's had the hardtop wires in the harness. Not true. My son't 93 only has the rear light wiring. I'll have to run some trailer wire back for the light and wiper. Here's a few pics. Look how clean those cooling passes are!