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Unread 11-26-2014, 10:48 PM   #1
jrlegacy23
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Join Date: Nov 2007
Location: Cooperstown, NY
Posts: 15
Back to a TJ, now doing a 2.5 to 4.0 swap

I used to have an 03 Wrangler, Freedom Edition. 3 budget lift and 33's. I sold it and moved on with a family. My kids are older now and the have been successfully brainwashed into wanting a Wrangler. I got a descent deal on a rust free 97 TJ with a knocking 2.5L, 5 speed about 2 weeks ago. I also got a good deal on a 96 Cherokee with a 4.0L 5 speed($400).

I spent the last few days pulling the 25 eng/trans/tcase and the 4.0 eng/trans/tcase. The TJ was a nice easy pull, the XJ on the other hand can kiss my @ss. That thing was the biggest PITA to pull out. Anything that could get hung up, did. I ended grabbing the torch and cutting everything out of the way.

Here are a few pics of the TJ I bought.

97-1.jpg   97-11.jpg   97-9.jpg  
97-6.jpg

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Unread 11-26-2014, 10:57 PM   #2
jrlegacy23
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The TJ has a 3.5" suspension lift, 1" body lift, custom front/rear bumpers, swing out tire carrier, bushwacker flat fender flares, and 33x12.5 BFG M/Ts.


The plan is to use the XJ computer, TJ wiring harness but adding 2 fuel injectors to the computer pins and make my own motor mounts. After I puled the 4.0 I puta few new parts on just because it was out. I put all new gaskets, including the head gasket and head bolts. I also put in a new oil pan (I may have popped a hole in the XJ one when I dropped the motor on the front diff), a new stainless steel header, a quick paint job and put in a new Melling oil pump.
Wish me luck on the rest of this headache
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Unread 11-29-2014, 03:10 PM   #3
jrlegacy23
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Here is about where I am now. Just cleaned the engine, put all new gaskets in, new pressure plate, clutch, and flywheel. Then threw on a fresh coat of black engine paint:
97-no-engine.jpg   jeep-engine.jpg  
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Unread 11-29-2014, 03:13 PM   #4
jrlegacy23
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Here is the engine before I painted it
unpainted-engine.jpg  
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Unread 12-07-2014, 09:15 PM   #5
jrlegacy23
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A week of hard work, blood, sweat, and tears..... the wife getting on my case for a while and then this is how it ends
rubi2.jpg  
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Unread 12-07-2014, 09:42 PM   #6
blitz134
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2006 LJ Wrangler 
 
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Location: Orange, CA
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Is this a replacement Jeep for your previous two jeeps (TJ + XJ) or the wife's new Jeep?
__________________
2006 LJ Rubicon: Just started the build

1990 YJ - Trying to sell - Previous Build
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Unread 12-07-2014, 09:47 PM   #7
jrlegacy23
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This is my replacement, It is a starting point an unbelievable cheap price for what it is. I am finishing up the motor swap in the TJ and it is already sold.
The XJ is crusher bound with no floorboards, rear frame rotted, and only glass being a usable part left on it.
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Unread 12-11-2014, 10:03 PM   #8
jrlegacy23
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I figured that I would still finish the motor swap on here so people can use it for a reference. As far as the wiring goes, I got a print out of the Jeep 2.5 harness and the 4.0 harness. The wiring colors are all the same and the harnesses are all the same except the 4.0 had two extra fuel injectors that get wired into the harness where the pins go into the computer. The problem that I found from the 6 cylinder to the 4 cylinder is that just about all the plug ins are shaped different. Yes I could cut and splice, but I have a friend with an extra 1999 4.0 Jeep for parts, so I am pulling the harness off from that. Here are a couple pics of the motor mounts and engine in the Jeep
engine-1.jpg  
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Unread 12-11-2014, 10:06 PM   #9
jrlegacy23
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The drivers side motor mount, modified to fit without changing any steering brackets. These are the 2.5, 4cylinder cut off with a plasma cutter and welding back were I need them. I was also able to use the 4 cyl drive shafts.
engine-3.jpg  
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Unread 12-11-2014, 10:08 PM   #10
jrlegacy23
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Here is the passengers side mount. I had to put a spacer between the mount and frame to level it out side to side.
engine-2.jpg  
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Unread 12-12-2014, 01:04 PM   #11
jrlegacy23
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I found out that the wiring harness from my buddy's 99 TJ is different from a 97-98 TJ. So I just got a new/use harness for a 97-98 4.0 TJ from Ebay. Hopefully this will be running when it comes.
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