Main reason I was doing this is since I was doing a paintjob on the Jeep I decided to change things up a bit and also gain some hood height for my upcoming engine replacement and lift, plus decent space for an electric fan. The two options I looked at was a DJ grill, or tube out the fronta bit and do some KJ grill kinda crap, but the TJ front seemed like a good option. So instead of bugging the crap out of the YJ, this is the approach I took
Here is a "before" pic:
here is a in progress picture:
Here is an after picture:
Here are some instructions.
-TJ hood and grill
-TJ hood hinges
-TJ hood tie-downs (plastic)
-TJ headlights, bezels, etc (J&W Thanks Neil and Imkfused for the tip
-TJ grill to cowl rods (the YJ's are too short)
-Misc bolts and washers
1- Remove the YJ hood
2- To remove the grill, you will need to disconnect the headlights, AC radiator if you have one, and disconnect the radiator
3- Install and mock up the grill, making sure that it aligns close with the YJ fenders. It takes a bit of pressure to bring the TJ grill to position
4- For a good fit, you will need to redrill holes to the TJ grill, so it aligns well.
5- Mount the radiator in the stock positions. You may need to do some light realignment.
6- Optional: I installed a junkyard electric fan on the TJ grill, so I can keep the stock mechanic fan, and on the trail also enable the electric fan as needed. The TJ grill seems slightly taller than the YJ, plus if you find a small enough fan, you can install it right inside the grill.
7- Mock the TJ hood in place.
8- In order to use the TJ hinges, you will need to drill the YJ cowl since the TJ hood hinge position is offset. (see pics). You will also need to bend the stock TJ hinges so the angle in their back is reduced and they will sit flush in the cowl. I used a BFH (Big F...ing hammer), and a couple of good hits and it was flat and in perfect shape).
9-Now it is the time to do the actuall install, make sure to measure twice and do it once
Use masking tape as reference markings. If you have body lifts, etc the TJ grill is taller, so you will need to compensate the difference in height somehow (i.e cut a bit of the BL off, etc.
10- Pay attention to your engine fan, make sure it turns freely and is not touching the fan shroud. Mine was slightly off and I had to do some minor adjusting (read cutting)
11- I am hoping to finish the install in a few days, so I will keep ya posted on any additional findisngs, but it is basically done, aside from a few more screws here and there, and some adjusting. Putting the TJ hood locks on will be the last step.
-the TJ hood will obviously not fit perfectly 100% (slightly wider in the back since the TJ cowl is some milimiter wider). You can either leave as is, or re-arch the back of the hood with some minor tough love)
-all of the stock YJ electrical fittings will work for the TJ. You will need to make a decision here as far as turn markers. Since my Jeep is flatfendered, I will need to install some front turn markers. I am not sure yet what direction I am going on that, most likely use some CJ style markers on the TJ grill.
In progress pics 2:
and almost done:
I will post pics as soon as it is finished up.